EP2918719B1 - Method for homogenising the puncture pattern in a needled nonwoven fabric - Google Patents
Method for homogenising the puncture pattern in a needled nonwoven fabric Download PDFInfo
- Publication number
- EP2918719B1 EP2918719B1 EP14159491.1A EP14159491A EP2918719B1 EP 2918719 B1 EP2918719 B1 EP 2918719B1 EP 14159491 A EP14159491 A EP 14159491A EP 2918719 B1 EP2918719 B1 EP 2918719B1
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- EP
- European Patent Office
- Prior art keywords
- needle
- needling
- woven fabric
- needling unit
- needle board
- Prior art date
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- 238000000034 method Methods 0.000 title claims description 28
- 239000004745 nonwoven fabric Substances 0.000 title claims description 21
- 230000005291 magnetic effect Effects 0.000 claims description 16
- 238000001514 detection method Methods 0.000 claims description 10
- 230000005693 optoelectronics Effects 0.000 claims description 6
- 230000033228 biological regulation Effects 0.000 claims description 2
- 230000006978 adaptation Effects 0.000 description 14
- 230000007547 defect Effects 0.000 description 11
- 238000006073 displacement reaction Methods 0.000 description 8
- 230000005294 ferromagnetic effect Effects 0.000 description 6
- 230000007246 mechanism Effects 0.000 description 5
- 230000008901 benefit Effects 0.000 description 3
- 125000004122 cyclic group Chemical group 0.000 description 3
- 238000000265 homogenisation Methods 0.000 description 2
- 230000035515 penetration Effects 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 1
- 230000035508 accumulation Effects 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 230000001627 detrimental effect Effects 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000011022 operating instruction Methods 0.000 description 1
- 230000010363 phase shift Effects 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- 230000001360 synchronised effect Effects 0.000 description 1
Images
Classifications
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H18/00—Needling machines
- D04H18/02—Needling machines with needles
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
Definitions
- the present invention relates to a method for homogenizing the stitching pattern in a needled nonwoven.
- the present invention has for its object to uniform the arrangements of the puncture points in a needled nonwoven and thus to arrive at a homogeneous puncture pattern.
- the adaptation of the at least one operating parameter and / or of the at least one structural parameter of the second needling device takes place by means of automatic control or regulation. This eliminates the need for the operator laborious manual adjustments and tedious test drives.
- the at least one operating parameter of the second needling device comprises, for example, the advancement of the fleece per stroke of the at least one needle board. Since the variations in the transport speed of the web are relatively low, the adjustment is made primarily by adjusting the vertical stroke frequency of the drive for the needle board.
- the at least one operating parameter of the second needling device may also include the phase of the vertical drive of the at least one needle board. In this way, a phase difference can be generated for the vertical drive of the needle board in the first needling device. By adjusting the phase, the puncturing positions of the needles in the second needling device can be varied, if at the same time the transport speed of the fleece by the second needling device remains constant.
- the at least one structural parameter of the second needling device may comprise the distance to the first needling device in a transport direction of the fleece. It is particularly preferred if this distance is adjustable during operation of the system.
- the at least one structural parameter of the second needling device can also comprise the lateral positioning of the at least one needle board in the second needling device transversely to a transport direction of the fleece. This is particularly advantageous if there are longitudinal strips in the nonwoven fabric after the first needling device.
- the lateral displacement of the at least one needle board in the second needling device can take place during operation of the system.
- the at least one structural parameter of the second needling device can also comprise the needle arrangement in the at least one needle board.
- the variable needle arrangement almost any pattern can be compensated in the stitching image of the web.
- the needles are horizontally displaceable in the region of the at least one needle board. In this way, an adjustment of the needle assembly in the needle board can be done in a particularly simple and guided manner.
- the at least one needle board has a base plate and a plurality of needle modules held on the base plate, each of which has a carrier element equipped with one or a plurality of needles, the individual needle modules being horizontally displaceable in the needle board.
- the carrier element may consist of a plastic injection-molded onto the needles.
- the second needling device may comprise on a needle bar at least one magnetic plate which serves for detachably fixing needles, needle modules and / or needle board segments on the side opposite the needle points.
- a particularly variable arrangement of the needles in the second needling device becomes possible.
- This arrangement also provides the further advantage that the magnetic plate automatically attracts all needles, needle modules and / or Nadelbrettsegmente without further fasteners simultaneously.
- the needles in the at least one needle board are vertically displaceable. In this way, certain needles in the second needling device at a given vertical stroke in the web to be consolidated engage, while other needles, which are pulled back a little further into the needle board, the vertical lift out of engagement with the fleece and thus do not create punctures in the fleece.
- the detection of puncture defects in the nonwoven preferably takes place by means of an optoelectronic method, in particular by means of a digital scan of the surface of the needled nonwoven.
- a CCD camera can be used.
- the adaptation of the at least one operating parameter and / or the at least one structural parameter of the second needling device takes place with the aid of data stored in an electronic library.
- the intelligent system can make a suggestion for the adaptation of the at least one operating parameter and / or the at least one structural parameter of the second needling device, or control or even regulate this adaptation.
- a detection of the puncture homogeneity is carried out in the needle-punched fleece, for example by means of an optoelectronic method.
- the result of the adaptation of the at least one operating parameter and / or the at least one structural parameter of the second needling device can be checked on the basis of the final result obtained.
- the results of the detection of the puncture homogeneity in the needled nonwoven behind the second needling device can additionally be used for a fine adjustment of the at least one operating parameter and / or of the at least one structure parameter of the second needling device.
- a feedback of this result takes place on the control device of the second needling device. In other words, a fully automatic, self-adjusting control is thereby achieved.
- Fig. 1 is an example of a plant for carrying out the method according to the invention for homogenizing the Einich image in a needled nonwoven fabric shown schematically.
- the system comprises a first needling device 2 and a second needling device 4, which are arranged in the transport direction T of the fleece 6 in series and serve for needling the fleece 6.
- the first needling device 2 has at least one movable needle board 8, to which needles 10 for needling the supplied fleece 6 are fastened.
- a take-off device 12 is provided for the fleece 6, here in the form of two draw-off rollers moved in opposite directions, which are driven at a speed v 1 .
- the second needling device 4 likewise has at least one movable needle board 14, to which needles 16 are fastened for further needling of the fleece 6 which has been previously needled in the first needling device 2.
- Downstream of the second needling device 4 is again a take-off device 18, preferably consisting of a pair of oppositely driven take-off rolls arranged, which withdraws the web 6 at a speed v 2 from the second needling device 4.
- the withdrawal speed v 2 of the withdrawal device 18 is slightly greater than the withdrawal speed v 1 of the withdrawal device 12.
- needleling in the context of the present invention may refer both to a needle machine with a single driven needle board, as well as a needle machine with two needle boards, one of which is above and one below the needled needle 6 and their needles thus towards each other and move away from each other.
- needleling may also include a needle machine with a plurality of needle boards arranged in series above and / or below the web 6, as well as corresponding needle machines each having a plurality of pairs of above or below the web 6 arranged needle boards.
- needleling device may also be directed to a single needle board or a particular pair of needle boards within a needle machine, even if the needle machine includes at least one other needle board adjacent to said needle board or boards.
- needle device can designate both all needle units within a needle machine, but also only certain units within a plurality of needle units in the same needle machine.
- inventive method is in all these cases, taking into account the respective different interpretation of the term “needling” executable.
- a detector 20 for detecting puncture defects in the previously needled by the first needling 2 web 6 is arranged.
- the detector 20 is therefore arranged downstream of the first needling device 2, either as in FIG Fig. 1 shown, in an area downstream of the trigger device 12, or else in a region between the first needling device 2 and the associated trigger device 12.
- the detector 20 is preferably configured as an optoelectronic sensor, for example as a CCD camera, which performs a digital scan of the surface of the needle-punched fleece 6 performs.
- the detector 20 is connected to a control device 22, which evaluates the results of the detection of the puncture defects in the fleece 6 and calculates a suitable adaptation of at least one operating parameter and / or at least one structural parameter of the second needling device 4, so that during further needling of the fleece 6 in the second needling device 4 at least parts of the puncture defects are selectively filled.
- a control device 22 evaluates the results of the detection of the puncture defects in the fleece 6 and calculates a suitable adaptation of at least one operating parameter and / or at least one structural parameter of the second needling device 4, so that during further needling of the fleece 6 in the second needling device 4 at least parts of the puncture defects are selectively filled.
- the provision or application of the information for the suitable adaptation of the at least one operating parameter and / or the at least one structural parameter of the second needling device 4 can be varied by the control device 22 Done way.
- an operating instruction for an operator for the purposeful manual setting of the at least one operating parameter and / or of the at least one structural parameter of the second needling device 4 can take place on a screen 24.
- the control device 22 automatically calculates not only a suitable adaptation of the at least one operating parameter and / or at least one structural parameter of the second needling device 4 but also the corresponding one based on stored data and laws stored in an electronic library Hiring also independently.
- the screen 24 may serve in this latter case for displaying information to the operator or completely eliminated.
- a further detector 26 for detecting the puncture homogeneity in the needle-punched fleece 6 is arranged, which serves to check the final needling needle result.
- the detector 26 is preferably an optoelectronic sensor, for example a CCD camera, with which the homogeneity of the punctures in the needled nonwoven 6 can be detected.
- the recordings of the detector 26 are output on a further screen 28 or on the first screen 24. It is particularly preferred if the results of the detector 26 are fed to the control device 22, whereby a control loop is produced.
- the control device 22 can thus use this information when adapting the at least one operating parameter and / or the at least one structural parameter of the second needling device 4.
- control device 22 only has to make a fine adjustment of the at least one operating parameter and / or of the at least one structural parameter of the second needling device 4 until a satisfactory result has been achieved in the finished needled web 6.
- the process according to the invention proceeds as follows. First, the fleece 6 is transported through the first needling device 2, in which a first needling of the fleece 6 takes place.
- the operating parameters of the first needling device 2 are set to a desired predetermined value. Subsequently, puncture defects in the fleece are detected in a region between the first needling device 2 and the second needling device 4 by means of the detector 20.
- the first needle-punching device 2 is used beforehand needled 6 further needled in the second needling device 4, wherein at least one operating parameter and / or at least one structural parameter of the second needling 4 is adjusted on the basis of the result of the detection of puncture defects in the nonwoven 6 by means of the detector 20 such that the further Needling the fleece 6 in the second needling device 4 at least parts of the puncture defects are selectively filled.
- the stitch pattern can be homogenized in needled web 6 and the product quality of the finished needled web improved.
- a possible operating parameter of the second needling device 4, which can be adapted to homogenize the stitching pattern in the needled web 6, is the horizontal feed of the web 6 per vertical stroke of the at least one needle board 14 of the second needling device 4.
- the speed v 2 of the trigger device 18 are influenced (see Fig. 1 ).
- a higher or lower withdrawal speed v 2 changes at the same stroke frequency of the needle board 14, the ratio of feed to stroke in the second needling 4.
- larger changes in the speed v 2 of the trigger 18 also inevitably affect the throughput of the overall machine, which is usually predetermined and should not be changed.
- the adjustment of the operating parameter "feed per stroke" of the second needling device 4 will be effected primarily by varying the vertical stroke frequency of the second needling device 4.
- the control device 22 can preferably be applied directly to the drive 30 (FIG. Fig. 2 ) of the needle board 14 of the second needling device 4.
- the adaptation of the operating parameter "feed per stroke” can also be carried out while the system is in operation.
- Fig. 2 an example of the embodiment of a second needling device 4 is shown.
- at least one vertical connecting rod 32 is cyclically moved up and down via an eccentric drive 30.
- the at least one vertical connecting rod 32 is usually hingedly connected to a needle bar 34 on which in turn the needle board 14 (in Fig. 2 not shown) is attached.
- the second needling device 4 is designed as a double needle machine having two vertical connecting rod 32 and two needle bar 34 with attached needle boards 14 which are arranged in the transport direction T of the web 6 in series.
- the movement of the two needle bars 34 takes place synchronously.
- the stroke frequency f of the eccentric drive 30 is changed.
- the second needling device 4 can also have a different number of vertical connecting rods 32 and needle bars 34 (in particular only one connecting rod and one needle bar).
- the method according to the invention is also applicable to any other form of needling devices, in particular also those which show only little or no horizontal lifting component.
- phase ⁇ of the vertical drive 30 of the at least one needle board 14 is interesting.
- a phase shift of 180 ° in this context means that the second needling device 4 has reached its respective highest point of the vertical stroke exactly when the first needling device 2 has reached the lowest point of its vertical stroke.
- a possible structural parameter of the second needling device 4, whose adaptation can lead to a homogenization of the stitching pattern of the needled web 6, is, for example, the distance of the second needling device 4 to the first needling device 2 in the transporting direction T of the web 6 Fig. 3a and 3b an exemplary arrangement for adjusting the position of the second needling device 4 in the transport direction T is shown.
- Components of the second needling device 4 shown here additionally comprise an eccentric arrangement 36 with which a substantially horizontally arranged connecting rod 38 can be moved in the transport direction T of the fleece 6 or in the opposite direction and then fixed.
- the connecting rod 38 is pivotally connected to the needle bar 34 in order not to restrict the operation of the second Vernadelungseinrichung 4.
- Another structural parameter of the second needling device 4, which according to the invention can be adapted for homogenizing the stitching pattern of the needled web 6, is the lateral positioning of the at least one needle board 14 in the second needling device 4 transversely to the transport direction T of the web 6.
- An example of a suitable displacement mechanism is in Fig. 4 shown.
- the displacement mechanism comprises a spindle arrangement 40 with the aid of which the needle board 14 of the second needling device 4 can be displaced transversely to the transport direction T of the fleece 6.
- the spindle arrangement 40 can preferably be driven via a drive controlled by the control device 22. This adjustment can be made while the system is in operation.
- the displacement mechanism engages the needle bar 34 of the needling device 4, but it is also possible for the lateral displacement mechanism to be directly connected to a needle board 14 pneumatically clamped to the needle bar 34.
- a further structural parameter of the second needling device 4, whose adaptation can lead to a homogenization of the stitching pattern in the needled web 6, is the needle arrangement in the at least one needle board 14 of the second needling device 4. Since a needle board contains many possible needle positions, the variability in the needle arrangement forms a particularly effective variant for improving the penetration pattern.
- a first option for varying the needle assembly in the needle board 14 is the targeted partial assembly of a conventional needle board 14 with needles 16, which are introduced only in the calculated by the controller 22 holes while other holes of the needle board 14 remain free.
- the targeted partial placement of the needle board 14 can be carried out manually or by means of a placement machine, which is controlled by the control device 22.
- Another option for varying the needle arrangement in the needle board 14 is an arrangement in which the needles 16 are horizontally displaceable in the region of the at least one needle board 14. To implement this principle, there are several possibilities.
- the illustrated needle board 14 here comprises a base plate 41, in which a plurality of horizontally extending slots 42 are arranged.
- a plurality of horizontally extending slots 42 are arranged.
- four slots are shown, two in a first direction and two further in a second direction perpendicular to the first direction.
- the arrangement of the slots 42 in the needle board is arbitrary and the slots 42 may be in any number and extend in any direction.
- needle modules 44 are arranged horizontally displaceable.
- Each needle module 44 in this case comprises a carrier element 46, preferably made of plastic, which has one or more recesses 47 in which the shafts of one or more needles 16 are introduced.
- the carrier element 46 may be injection-molded onto the needles 16, for example.
- Each slot 42 preferably has in its wall portion a circumferential shoulder 48, as best in the broken area in the lower left in Fig. 5 you can see. On these shoulders 48 are projecting edge portions 50 of the support member 46. Further design possibilities of needle modules 44 are in EP 2 138 616 A1 or EP 2 138 617 A1 described, the content of which is hereby incorporated by reference in its entirety.
- the individual needle modules 44 can now be displaced in the slots 42, and after reaching the correct sliding position, the needle modules 44 are moved by forces between the needle board 14 and the associated needle bar 34 (FIG. Fig. 1 ) clamped. How out Fig. 5 As can be seen, a plurality of needle modules 44 can also be arranged in a slot 42.
- a magnetic plate 52 is attached to the needle bar 34.
- the needle board 14 consists of several ferromagnetic needle board segments 54 which are fixable to the magnetic disk 52.
- the Nadelbrettsegmente 54 are arranged transversely to the transport direction T of the web 6 and define between them respective slots 42 for receiving needle modules 44.
- Each needle module 44 includes a plurality of needles 16 which are connected to a support member 46.
- the support member 46 may, as in Fig. 6 shown, slightly projecting down from the associated slot 42, but it may also be completely received in the slot 42.
- the support member 46 In its end region, the support member 46 has a widened head portion 56 which is slidably received and guided in a corresponding widened portion of the associated slot 42. Preferably, at least the head portion 56 is ferromagnetic. In the installed state, the head sections 56 of the needle modules 44 are then fixed to the magnetic plate 52.
- EP 2 138 617 A1 or EP 2 138 616 A1 referenced, the contents of which should be fully incorporated by reference.
- each needle module 44 comprises only one needle 16, but it may also comprise a plurality of needles 16.
- Each needle module 44 has a head portion 56 which is ferromagnetic.
- the needle modules 44 are displaceable or can be repositioned; when the magnetic plate 52 is switched on, they are fixed to the magnetic plate 52 at any point. Gaps between individual needle modules 44 can be bridged by intermediate pieces 58 in order to achieve stabilization.
- the intermediate pieces 58 may preferably also be ferromagnetic.
- Fig. 8a variant shown shows individual Nadelbrettsegmente 54, at least some of which are ferromagnetic and are fixed to a magnetic plate 52.
- the needle board segments 54 have recesses 60 (see plan view in FIG Fig. 8b ), which serve for variable recording of individual needles 16.
- the recesses 60 are in this case formed in an edge region of the respective needle board segment 54, so that the respective recess 60 in the installed state according to Fig. 8a is limited by the adjacent needle board segment 54.
- the individual needles 16 are thus held between each two Nadelbrettsegmenten 54 and the magnetic plate 52 fixed in the recess 60.
- a clamping force can be applied, for example via a pneumatically activated air hose 62. This is particularly necessary if some of the needle board segments 54 are not magnetically adhere to the magnetic disk 52, because they are made of plastic, for example or aluminum are formed.
- a bracing device can also in the embodiment according to Fig. 7 be used.
- variable needle arrangement in the needle board 14 is to move the needles 16 in at least one needle board 14 vertically.
- An example of such a configuration is in Fig. 9 shown. In this case, the front right corner region of the needle board 14 is shown broken off, so that the arrangement of the needles 16 in the interior of the needle board 14 is visible.
- the needle board 14 comprises three layers 64, 66 and 68, each having mutually aligned bores 70 for the individual needles 16.
- the needles 16 are arranged vertically displaceable within these bores 70, in such a way that they extend in each case through the lower layer 68 and the middle layer 66 into the upper layer 64 of the needle board 14, wherein they different depths in the upper layer 64 of the needle board 14 can be pushed.
- Fig. 9 are of the four illustrated needles 16, the two left needles less far into the upper layer 64 of the needle board 14 inserted as the two needles shown to the right thereof.
- the fixation of the needles 16 takes place in the illustrated example by several levers 72 which apply a horizontal force on the middle layer 66 of the needle board 14 and thus passing through the middle layer 66 through needles 16 with respect to the upper plate 64 and the lower plate 68 of the Tighten needle boards 14.
- the middle layer 66 of the needle board 14 may, as in the illustrated example, be integrally formed, or else segmented. With this arrangement, individual needles 16 can be adjusted in their height position and fixed there. The individual needles 16 are thus activated for engagement in the web 6 by being pulled down, and they are deactivated by being pushed upwards. There are several other possibilities of vertical displacement of the needles 16 in the needle board 14 conceivable.
- variable needle assembly in the needle board can be performed only when the machine is stopped.
- the operator is either displayed on a screen 24, the preferred arrangement of the needles 16 in the needle board 14 of the second Vernadelungseinrichung 4, which should set, or there are corresponding devices for automatically positioning the needles 16 in the needle board 14 by the controller 22 based on Results of the detector 20 driven.
- the adjustment of only one of the mentioned parameters may be sufficient or advantageous, but in the context of the invention several of the mentioned parameters can also be adapted simultaneously.
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Nonwoven Fabrics (AREA)
- Knitting Machines (AREA)
Description
Die vorliegende Erfindung betrifft ein Verfahren zur Homogenisierung des Einstichbildes bei einem vernadelten Vlies.The present invention relates to a method for homogenizing the stitching pattern in a needled nonwoven.
In der Vernadelungstechnik ist die Erscheinung bekannt, dass die im Nadelbrett entsprechend einem Schema fix angeordneten Nadeln abhängig vom horizontalen Vorschub des Vlieses pro vertikalem Hub der in das Vlies einstechenden Nadeln zu Einstichbildern in der Vliesoberfläche führen. Außerdem können beim Vernadeln Längsverzüge in der Vliesbahn auftreten. Ebenso sind Quereinsprünge zu nennen, die diese Einstichmuster beeinflussen. Nur in wenigen Vorschubbereichen gelingt es, einigermaßen gleichmäßige Einstichbilder zu erzeugen. Oft kommt es jedoch zu Querstreifen, Längsstreifen, Diagonalen oder regelrechten Musterungen, bei denen die Einstiche nicht äquidistant zueinander angeordnet sind. Statt dessen sind einerseits Anhäufungen und andererseits Einstich-Fehlstellen festzustellen. Für die Qualität des Endprodukts im Hinblick auf Festigkeit, Dichte, Abriebfestigkeit und Oberflächengleichmäßigkeit sind solche Einstichbilder schädlich.In the needling technique, the phenomenon is known that the needles fixed in the needle board according to a scheme depending on the horizontal feed of the web per vertical stroke of the piercing into the web needles lead to Einich images in the nonwoven surface. In addition, longitudinal distortion in the nonwoven web may occur during needling. Likewise, transverse jumps are to be mentioned which influence these puncturing patterns. Only in a few feed areas is it possible to produce reasonably uniform puncturing images. Often, however, it comes to horizontal stripes, vertical stripes, diagonals or regular patterns in which the punctures are not arranged equidistant from each other. Instead, on the one hand accumulations and on the other hand puncture defects are found. For the quality of the final product in terms of strength, density, abrasion resistance and surface uniformity such puncture images are detrimental.
Der vorliegenden Erfindung liegt die Aufgabe zugrunde, die Anordnungen der Einstichstellen bei einem vernadelten Vlies zu vergleichmäßigen und somit zu einem homogeneren Einstichbild zu gelangen.The present invention has for its object to uniform the arrangements of the puncture points in a needled nonwoven and thus to arrive at a homogeneous puncture pattern.
Erfindungsgemäß umfasst das Verfahren zur Homogenisierung des Einstichbildes in einem vernadelten Vlies folgende Schritte:
- Bereitstellen einer ersten Vernadelungseinrichtung und einer zweiten Vernadelungseinrichtung, die in Reihe angeordnet sind, wobei jede Vernadelungseinrichtung eine Vielzahl von an mindestens einem bewegbaren Nadelbrett befestigten Nadeln zum Vernadeln eines zugeführten Vlieses aufweist;
- Vernadeln des zugeführten Vlieses in der ersten Vernadelungseinrichtung, wodurch eine Vielzahl von Einstichen im Vlies erzeugt wird;
- Detektieren von Einstich-Fehlstellen im Vlies in einem Bereich zwischen der ersten Vernadelungseinrichtung und der zweiten Vernadelungseinrichtung;
- weiteres Vernadeln des von der ersten Vernadelungseinrichtung vernadelten Vlieses in der zweiten Vernadelungseinrichtung, wobei mindestens ein Betriebsparameter und/oder mindestens ein Strukturparameter der zweiten Vernadelungseinrichtung auf der Basis des Ergebnisses der Detektion von Einstich-Fehlstellen im Vlies derart angepasst wird, dass beim weiteren Vernadeln des Vlieses in der zweiten Vernadelungseinrichtung zumindest Teile der Einstich-Fehlstellen gezielt aufgefüllt werden.
- Providing a first needling device and a second needling device arranged in series, each needling device having a plurality of needles attached to at least one movable needle board for needling a fed nonwoven web;
- Needling the fed nonwoven fabric in the first needling means, thereby producing a plurality of punctures in the nonwoven fabric;
- Detecting puncture defects in the web in a region between the first needling device and the second needling device;
- further needle-punching of the nonwoven needled by the first needling device in the second needling device, wherein at least one operating parameter and / or at least one structural parameter of the second needling device is adjusted on the basis of the result of the detection of puncture defects in the fleece so that at least parts of the puncture defects are filled up in a specific manner during further needling of the fleece in the second needling device.
Auf diese Weise gelingt es, mit Hilfe elektronischer Unterstützung das Einstichbild in einem vernadelten Vlies hinsichtlich seiner Homogenität zumindest deutlich zu verbessern.In this way it is possible, with the help of electronic support, to at least significantly improve the penetration pattern in a needled nonwoven with regard to its homogeneity.
In einer bevorzugten Ausführungsform erfolgt die Anpassung des mindestens einen Betriebsparameters und/oder des mindestens einen Strukturparameters der zweiten Vernadelungseinrichtung mittels automatischer Steuerung oder Regelung. Auf diese Weise entfallen für die Bedienperson aufwändige manuelle Einstellarbeiten und langwierige Testfahrten.In a preferred embodiment, the adaptation of the at least one operating parameter and / or of the at least one structural parameter of the second needling device takes place by means of automatic control or regulation. This eliminates the need for the operator laborious manual adjustments and tedious test drives.
Der mindestens eine Betriebsparameter der zweiten Vernadelungseinrichtung umfasst beispielsweise den Vorschub des Vlieses pro Hub des mindestens einen Nadelbretts. Da die Variationsmöglichkeiten bei der Transportgeschwindigkeit des Vlieses relativ gering sind, erfolgt die Einstellung in erster Linie durch Anpassung der vertikalen Hubfrequenz des Antriebs für das Nadelbrett.The at least one operating parameter of the second needling device comprises, for example, the advancement of the fleece per stroke of the at least one needle board. Since the variations in the transport speed of the web are relatively low, the adjustment is made primarily by adjusting the vertical stroke frequency of the drive for the needle board.
Der mindestens eine Betriebsparameter der zweiten Vernadelungseinrichtung kann auch die Phase des vertikalen Antriebs des mindestens einen Nadelbretts umfassen. Auf diese Weise kann ein Phasenunterschied zum vertikalen Antrieb des Nadelbretts in der ersten Vernadelungseinrichtung erzeugt werden. Durch Einstellung der Phase können die Einstichpositionen der Nadeln in der zweiten Vernadelungseinrichtung variiert werden, wenn gleichzeitig die Transportgeschwindigkeit des Vlieses durch die zweite Vernadelungseinrichtung konstant bleibt.The at least one operating parameter of the second needling device may also include the phase of the vertical drive of the at least one needle board. In this way, a phase difference can be generated for the vertical drive of the needle board in the first needling device. By adjusting the phase, the puncturing positions of the needles in the second needling device can be varied, if at the same time the transport speed of the fleece by the second needling device remains constant.
Der mindestens eine Strukturparameter der zweiten Vernadelungseinrichtung kann den Abstand zur ersten Vernadelungseinrichtung in einer Transportrichtung des Vlieses umfassen. Besonders bevorzugt ist es, wenn dieser Abstand im laufenden Betrieb der Anlage verstellbar ist.The at least one structural parameter of the second needling device may comprise the distance to the first needling device in a transport direction of the fleece. It is particularly preferred if this distance is adjustable during operation of the system.
Der mindestens eine Strukturparameter der zweiten Vernadelungseinrichtung kann auch die seitliche Positionierung des mindestens einen Nadelbretts in der zweiten Vernadelungseinrichtung quer zu einer Transportrichtung des Vlieses umfassen. Dies ist insbesondere vorteilhaft, wenn nach der ersten Vernadelungseinrichtung Längsstreifen im Vlies vorliegen. Vorteilhafterweise kann die seitliche Verschiebung des mindestens einen Nadelbretts in der zweiten Vernadelungseinrichtung im laufenden Betrieb der Anlage erfolgen.The at least one structural parameter of the second needling device can also comprise the lateral positioning of the at least one needle board in the second needling device transversely to a transport direction of the fleece. This is particularly advantageous if there are longitudinal strips in the nonwoven fabric after the first needling device. Advantageously, the lateral displacement of the at least one needle board in the second needling device can take place during operation of the system.
In einer speziellen Ausgestaltung kann der mindestens eine Strukturparameter der zweiten Vernadelungseinrichtung auch die Nadelanordnung im mindestens einen Nadelbrett umfassen. Durch die variable Nadelanordnung können nahezu beliebige Muster im Einstichbild des Vlieses ausgeglichen werden.In a special embodiment, the at least one structural parameter of the second needling device can also comprise the needle arrangement in the at least one needle board. By the variable needle arrangement almost any pattern can be compensated in the stitching image of the web.
In einer bevorzugten Ausführungsform sind dabei die Nadeln im Bereich des mindestens einen Nadelbretts horizontal verschiebbar. Auf diese Weise kann eine Verstellung der Nadelanordnung im Nadelbrett auf besonders einfache und geführte Weise erfolgen.In a preferred embodiment, the needles are horizontally displaceable in the region of the at least one needle board. In this way, an adjustment of the needle assembly in the needle board can be done in a particularly simple and guided manner.
Bevorzugt ist es, wenn das mindestens eine Nadelbrett eine Grundplatte und eine Mehrzahl von an der Grundplatte gehaltenen Nadelmodulen aufweist, von denen jedes ein Trägerelement aufweist, das mit einer oder einer Mehrzahl von Nadeln ausgestattet ist, wobei die einzelnen Nadelmodule im Nadelbrett horizontal verschiebbar sind. Das Trägerelement kann dabei aus einem an die Nadeln angespritzten Kunststoff bestehen.It is preferred if the at least one needle board has a base plate and a plurality of needle modules held on the base plate, each of which has a carrier element equipped with one or a plurality of needles, the individual needle modules being horizontally displaceable in the needle board. The carrier element may consist of a plastic injection-molded onto the needles.
Alternativ kann die zweite Vernadelungseinrichtung an einem Nadelbalken mindestens eine Magnetplatte aufweisen, die zur lösbaren Festlegung von Nadeln, Nadelmodulen und/oder Nadelbrettsegmenten an der den Nadelspitzen gegenüberliegenden Seite dient. Hierdurch wird eine besonders variable Anordnung der Nadeln in der zweiten Vernadelungseinrichtung möglich. Diese Anordnung liefert auch den weiteren Vorteil, dass die Magnetplatte ohne weitere Befestigungselemente automatisch sämtliche Nadeln, Nadelmodule und/oder Nadelbrettsegmente gleichzeitig anzieht.Alternatively, the second needling device may comprise on a needle bar at least one magnetic plate which serves for detachably fixing needles, needle modules and / or needle board segments on the side opposite the needle points. As a result, a particularly variable arrangement of the needles in the second needling device becomes possible. This arrangement also provides the further advantage that the magnetic plate automatically attracts all needles, needle modules and / or Nadelbrettsegmente without further fasteners simultaneously.
Ebenso ist es denkbar, dass die Nadeln im mindestens einen Nadelbrett vertikal verschiebbar sind. Auf diese Weise können bestimmte Nadeln in der zweiten Vernadelungseinrichtung bei einem vorgegebenen Vertikalhub in das zu verfestigende Vlies eingreifen, während andere Nadeln, die etwas weiter ins Nadelbrett zurückgezogen sind, beim Vertikalhub außer Eingriff mit dem Vlies sind und somit keine Einstiche im Vlies erzeugen.It is also conceivable that the needles in the at least one needle board are vertically displaceable. In this way, certain needles in the second needling device at a given vertical stroke in the web to be consolidated engage, while other needles, which are pulled back a little further into the needle board, the vertical lift out of engagement with the fleece and thus do not create punctures in the fleece.
Die Detektion von Einstich-Fehlstellen im Vlies erfolgt vorzugsweise mittels eines optoelektronischen Verfahrens, insbesondere mittels eines digitalen Scans der Oberfläche des vernadelten Vlieses. Hierfür kann beispielsweise eine CCD-Kamera verwendet werden.The detection of puncture defects in the nonwoven preferably takes place by means of an optoelectronic method, in particular by means of a digital scan of the surface of the needled nonwoven. For this example, a CCD camera can be used.
In einer bevorzugten Ausführungsform erfolgt die Anpassung des mindestens einen Betriebsparameters und/oder des mindestens einen Strukturparameters der zweiten Vernadelungseinrichtung unter Zuhilfenahme von in einer elektronischen Bibliothek hinterlegten Daten. Durch Vergleich mit diesen gespeicherten Erfahrungswerten kann das intelligente System einen Vorschlag für die Anpassung des mindestens einen Betriebsparameters und/oder des mindestens einen Strukturparameters der zweiten Vernadelungseinrichtung abgeben, diese Anpassung steuern oder sogar regeln.In a preferred embodiment, the adaptation of the at least one operating parameter and / or the at least one structural parameter of the second needling device takes place with the aid of data stored in an electronic library. By comparison with these stored empirical values, the intelligent system can make a suggestion for the adaptation of the at least one operating parameter and / or the at least one structural parameter of the second needling device, or control or even regulate this adaptation.
Hinter der zweiten Vernadelungseinrichtung wird im vernadelten Vlies vorzugsweise eine Detektion der Einstich-Homogenität vorgenommen, beispielsweise mittels eines optoelektronischen Verfahrens. Auf diese Weise kann das Ergebnis der Anpassung des mindestens einen Betriebsparameters und/oder des mindestens einen Strukturparameters der zweiten Vernadelungseinrichtung anhand des erzielten Endergebnisses überprüft werden.Behind the second needling device, preferably a detection of the puncture homogeneity is carried out in the needle-punched fleece, for example by means of an optoelectronic method. In this way, the result of the adaptation of the at least one operating parameter and / or the at least one structural parameter of the second needling device can be checked on the basis of the final result obtained.
In einer besonders bevorzugten Ausführungsform können die Ergebnisse der Detektion der Einstich-Homogenität im vernadelten Vlies hinter der zweiten Vernadelungseinrichtung zusätzlich für eine Feinanpassung des mindestens einen Betriebsparameters und/oder des mindestens einen Strukturparameters der zweiten Vernadelungseinrichtung verwendet werden. Dabei erfolgt eine Rückkopplung dieses Ergebnisses auf die Steuereinrichtung der zweiten Vernadelungseinrichtung. Mit anderen Worten wird hierdurch eine vollautomatische, selbstjustierende Regelung erreicht.In a particularly preferred embodiment, the results of the detection of the puncture homogeneity in the needled nonwoven behind the second needling device can additionally be used for a fine adjustment of the at least one operating parameter and / or of the at least one structure parameter of the second needling device. In this case, a feedback of this result takes place on the control device of the second needling device. In other words, a fully automatic, self-adjusting control is thereby achieved.
Weitere Merkmale und Vorteile der Erfindung ergeben sich aus der nachfolgenden Beschreibung unter Bezugnahme auf die Zeichnungen.
- Fig. 1
- ist eine schematische Ansicht einer Anlage zur Durchführung des erfindungsgemäßen Verfahrens zur Homogenisierung des Einstichbildes bei einem vernadelten Vlies;
- Fig. 2
- ist eine schematische Querschnittsansicht eines Nadelaggregats in der zweiten Vernadelungseinrichtung;
- Fig. 3a und 3b
- sind zwei verschiedene Ansichten eines Nadelaggregats in der zweiten Vernadelungseinrichtung ähnlich dem aus
Fig. 2 , wobei zusätzlich eine horizontale Verschiebung des Nadelbretts der zweiten Vernadelungseinrichtung in einer Transportrichtung des Vlieses möglich ist; - Fig. 4
- ist eine schematische Perspektivansicht eines Nadelaggregats in der zweiten Vernadelungseinrichtung ähnlich dem aus
Fig. 2 , wobei zusätzlich eine seitliche Positionierung des mindestens einen Nadelbretts quer zu einer Transportrichtung des Vlieses möglich ist; - Fig. 5
- ist eine schematische Perspektivansicht eines Nadelbretts der zweiten Vernadelungseinrichtung, bei dem einzelne Nadelmodule horizontal verschiebbar in einer Trägerplatte des Nadelbretts angeordnet sind;
- Fig. 6
- ist eine schematische Perspektivansicht eines Nadelbretts der zweiten Vernadelungseinrichtung, bei dem mehrere zu einer Kammstruktur verbundene Nadeln verschiebbar im Nadelbrett angeordnet sind und durch eine Magnetplatte fixiert werden;
- Fig. 7
- ist eine schematische Perspektivansicht eines Ausschnitts eines Nadelaggregats der zweiten Vernadelungseinrichtung, bei dem ferromagnetische Köpfe der Nadeln in beliebiger Anordnung an einer Magnetplatte gehalten sind;
- Fig. 8a
- ist eine schematische Perspektivansicht eines Ausschnitts eines Nadelaggregats der zweiten Vernadelungseinrichtung, bei dem das Nadelbrett aus mehreren Nadelbrettsegmenten besteht, die an einer Magnetplatte gehalten sind;
- Fig. 8b
- ist eine Ansicht von oben auf zwei benachbarte der in
Fig. 8a dargestellten Nadelbrettsegmente; und - Fig. 9
- ist eine schematische Perspektivansicht eines Nadelaggregats in der zweiten Vernadelungseinrichtung, bei dem die einzelnen Nadeln vertikal verschiebbar sind.
- Fig. 1
- is a schematic view of a plant for carrying out the method according to the invention for homogenizing the Einichbildes in a needled nonwoven fabric;
- Fig. 2
- is a schematic cross-sectional view of a needle assembly in the second needling device;
- Fig. 3a and 3b
- are two different views of a needle assembly in the second needling similar to that
Fig. 2 , wherein in addition a horizontal displacement of the needle board of the second needling device in a transport direction of the web is possible; - Fig. 4
- is a schematic perspective view of a needle assembly in the second needling similar to that of
Fig. 2 , wherein additionally a lateral positioning of the at least one needle board transverse to a transport direction of the web is possible; - Fig. 5
- is a schematic perspective view of a needle board of the second needling device, in which individual needle modules are arranged horizontally displaceable in a carrier plate of the needle board;
- Fig. 6
- Figure 3 is a schematic perspective view of a needle board of the second needling apparatus in which a plurality of needles connected to a comb structure are slidably disposed in the needle board and fixed by a magnetic disk;
- Fig. 7
- is a schematic perspective view of a section of a needle assembly of the second needling device, are held in the ferromagnetic heads of the needles in any arrangement on a magnetic disk;
- Fig. 8a
- is a schematic perspective view of a section of a needle assembly of the second needling device, wherein the needle board consists of several Nadelbrettsegmenten, which are held on a magnetic disk;
- Fig. 8b
- is a top view of two adjacent ones in
Fig. 8a illustrated needle board segments; and - Fig. 9
- is a schematic perspective view of a needle assembly in the second needling device, in which the individual needles are vertically displaceable.
In
Die zweite Vernadelungseinrichtung 4 weist ebenfalls mindestens ein bewegbares Nadelbrett 14 auf, an dem Nadeln 16 zum weiteren Vernadeln des bereits in der ersten Vernadelungseinrichtung 2 zuvor vernadelten Vlieses 6 befestigt sind. Stromab der zweiten Vernadelungseinrichtung 4 ist wiederum eine Abzugseinrichtung 18, vorzugsweise bestehend aus einem Paar gegensinnig angetriebener Abzugswalzen, angeordnet, die das Vlies 6 mit einer Geschwindigkeit v2 aus der zweiten Vernadelungseinrichtung 4 abzieht. In der Regel ist die Abzugsgeschwindigkeit v2 der Abzugseinrichtung 18 etwas größer als die Abzugsgeschwindigkeit v1 der Abzugseinrichtung 12.The second needling device 4 likewise has at least one
Der Begriff "Vernadelungseinrichtung" kann im Rahmen der vorliegenden Erfindung sowohl eine Nadelmaschine mit einem einzigen angetriebenen Nadelbrett bezeichnen, ebenso eine Nadelmaschine mit zwei Nadelbrettern, von denen eines oberhalb und eines unterhalb des zu vernadelnden Vlieses 6 angeordnet ist und deren Nadeln sich somit aufeinander zu und voneinander weg bewegen. Außerdem kann der Begriff "Vernadelungseinrichtung" auch eine Nadelmaschine mit mehreren in Reihe oberhalb und/oder unterhalb des Vlieses 6 angeordneten Nadelbrettern umfassen, ebenso entsprechende Nadelmaschinen mit jeweils mehreren Paaren von oberhalb bzw. unterhalb des Vlieses 6 angeordneten Nadelbrettern.The term "needling" in the context of the present invention may refer both to a needle machine with a single driven needle board, as well as a needle machine with two needle boards, one of which is above and one below the needled
Schließlich kann der Begriff "Vernadelungseinrichtung" auch auf ein einzelnes Nadelbrett oder ein bestimmtes Paar von Nadelbrettern innerhalb einer Nadelmaschine gerichtet sein, auch wenn die Nadelmaschine neben dem genannten Nadelbrett bzw. den genannten Nadelbrettern noch mindestens ein weiteres Nadelbrett umfasst. Mit anderen Worten bedeutet dies, dass der Begriff "Vernadelungseinrichtung" sowohl sämtliche Nadelaggregate innerhalb einer Nadelmaschine bezeichnen kann, ebenso aber lediglich bestimmte Aggregate innerhalb einer Mehrzahl von Nadelaggregaten in derselben Nadelmaschine. Das erfindungsgemäße Verfahren ist in all diesen Fällen unter Berücksichtigung der jeweils unterschiedlichen Auslegung des Begriffes "Vernadelungseinrichtung" ausführbar.Finally, the term "needling device" may also be directed to a single needle board or a particular pair of needle boards within a needle machine, even if the needle machine includes at least one other needle board adjacent to said needle board or boards. In other words, this means that the term "needling device" can designate both all needle units within a needle machine, but also only certain units within a plurality of needle units in the same needle machine. The inventive method is in all these cases, taking into account the respective different interpretation of the term "needling" executable.
In einem Bereich zwischen der ersten Vernadelungseinrichtung 2 und der zweiten Vernadelungseinrichtung 4 ist ein Detektor 20 zur Detektion von Einstich-Fehlstellen im durch die erste Vernadelungseinrichtung 2 zuvor vernadelten Vlies 6 angeordnet. Der Detektor 20 ist also stromab der ersten Vernadelungseinrichtung 2 angeordnet, und zwar entweder, wie in
Der Detektor 20 ist mit einer Steuereinrichtung 22 verbunden, die die Ergebnisse der Detektion der Einstich-Fehlstellen im Vlies 6 auswertet und daraus eine geeignete Anpassung mindestens eines Betriebsparameters und/oder mindestens eines Strukturparameters der zweiten Vernadelungseinrichtung 4 berechnet, sodass beim weiteren Vernadeln des Vlieses 6 in der zweiten Vernadelungseinrichtung 4 zumindest Teile der Einstich-Fehlstellen gezielt aufgefüllt werden. Konkrete Beispiele für den mindestens einen Betriebsparameter und den mindestens einen Strukturparameter der zweiten Vernadelungseinrichtung 4 werden weiter unten detailliert erläutert, ebenso Möglichkeiten von deren Anpassung.The
Die Bereitstellung oder Anwendung der Informationen für die geeignete Anpassung des mindestens einen Betriebsparameters und/oder des mindestens einen Strukturparameters der zweiten Vernadelungseinrichtung 4 kann durch die Steuereinrichtung 22 auf vielfältige Weise erfolgen. Beispielsweise kann auf einem Bildschirm 24 eine Bedienungsanweisung für eine Bedienperson zum gezielten manuellen Einstellen des mindestens einen Betriebsparameters und/oder des mindestens einen Strukturparameters der zweiten Vernadelungseinrichtung 4 erfolgen. Ebenso ist es möglich, dass die Steuereinrichtung 22 automatisch aufgrund von hinterlegten Daten und Gesetzmäßigkeiten, die beispielsweise in einer elektronischen Bibliothek gespeichert sind, nicht nur eine geeignete Anpassung des mindestens einen Betriebsparameters und/oder mindestens einen Strukturparameters der zweiten Vernadelungseinrichtung 4 berechnet, sondern die entsprechende Einstellung auch selbständig vornimmt. Der Bildschirm 24 kann in diesem letzteren Fall zur Darstellung von Informationen für die Bedienperson dienen oder auch vollständig entfallen.The provision or application of the information for the suitable adaptation of the at least one operating parameter and / or the at least one structural parameter of the second needling device 4 can be varied by the
In einer bevorzugten Ausführungsform ist stromab der zweiten Vernadelungseinrichtung 4 noch ein weiterer Detektor 26 zur Detektion der Einstich-Homogenität im vernadelten Vlies 6 angeordnet, der zu einer Überprüfung des finalen Vernadelungs-Ergebnisses dient. Der Detektor 26 ist vorzugsweise ein optoelektronischer Sensor, beispielsweise eine CCD-Kamera, mit dem die Homogenität der Einstiche im vernadelten Vlies 6 erfasst werden kann. Vorzugsweise werden die Aufnahmen des Detektors 26 an einem weiteren Bildschirm 28 oder am ersten Bildschirm 24 ausgegeben. Besonders bevorzugt ist es, wenn die Ergebnisse des Detektors 26 der Steuereinrichtung 22 zugeführt werden, wodurch eine Regelschleife entsteht. Die Steuereinrichtung 22 kann diese Informationen somit bei der Anpassung des mindestens einen Betriebsparameters und/oder des mindestens einen Strukturparameters der zweiten Vernadelungseinrichtung 4 verwenden. Bevorzugt ist es, wenn durch die zurückgemeldeten Ergebnisse des Detektors 26 die Steuereinrichtung 22 lediglich eine Feinanpassung des mindestens einen Betriebsparameters und/oder des mindestens einen Strukturparameters der zweiten Vernadelungseinrichtung 4 vornehmen muss, bis ein zufriedenstellendes Ergebnis im fertig vernadelten Vlies 6 erzielt ist.In a preferred embodiment, downstream of the second needling device 4, a
Das erfindungsgemäße Verfahren läuft folgendermaßen ab. Zunächst wird das Vlies 6 durch die erste Vernadelungseinrichtung 2 transportiert, in der eine erste Vernadelung des Vlieses 6 stattfindet. Die Betriebsparameter der ersten Vernadelungseinrichtung 2 sind dabei auf einen gewünschten vorbestimmten Wert eingestellt. Anschließend erfolgt eine Detektion von Einstich-Fehlstellen im Vlies in einem Bereich zwischen der ersten Vernadelungseinrichtung 2 und der zweiten Vernadelungseinrichtung 4 mittels des Detektors 20. Schließlich wird das von der ersten Vernadelungseinrichtung 2 zuvor vernadelte Vlies 6 in der zweiten Vernadelungseinrichtung 4 weiter vernadelt, wobei mindestens ein Betriebsparameter und/oder mindestens ein Strukturparameter der zweiten Vernadelungseinrichtung 4 auf der Basis des Ergebnisses der Detektion von Einstich-Fehlstellen im Vlies 6 mittels des Detektors 20 derart angepasst wird, dass beim weiteren Vernadeln des Vlieses 6 in der zweiten Vernadelungseinrichtung 4 zumindest Teile der Einstich-Fehlstellen gezielt aufgefüllt werden. Auf diese Weise kann das Einstichbild im vernadelten Vlies 6 homogenisiert und die Produktqualität des fertig vernadelten Vlieses verbessert werden.The process according to the invention proceeds as follows. First, the
Im Folgenden sollen bevorzugte Betriebsparameter bzw. Strukturparameter der zweiten Vernadelungseinrichtung 4 und beispielhafte Möglichkeiten von deren Anpassung erläutert werden.In the following, preferred operating parameters or structural parameters of the second needling device 4 and exemplary possibilities of their adaptation will be explained.
Ein möglicher Betriebsparameter der zweiten Vernadelungseinrichtung 4, der zur Homogenisierung des Einstichbildes im vernadelten Vlies 6 angepasst werden kann, ist der horizontale Vorschub des Vlieses 6 pro vertikalem Hub des mindestens einen Nadelbretts 14 der zweiten Vernadelungseinrichtung 4. Hierzu kann beispielsweise die Geschwindigkeit v2 der Abzugseinrichtung 18 beeinflusst werden (siehe
In
In der in
Ein weiterer Betriebsparameter der zweiten Vernadelungseinrichtung 4, der zur Homogenisierung des Einstichbildes des vernadelten Vlieses 6 angepasst werden kann, ist die Phase ϕ des vertikalen Antriebs 30 des mindestens einen Nadelbretts 14. Insbesondere der Phasenunterschied der zyklischen Bewegung der zweiten Vernadelungseinrichtung 4 im Vergleich mit der zyklischen Bewegung der ersten Vernadelungseinrichtung 2 ist dabei interessant. Eine Phasenverschiebung von 180° bedeutet in diesem Zusammenhang, dass die zweite Vernadelungseinrichtung 4 ihren jeweils höchsten Punkt des Vertikalhubs genau dann erreicht hat, wenn die erste Vernadelungseinrichtung 2 den tiefsten Punkt ihres Vertikalhubs erreicht hat. Durch eine Einstellung der Phase ϕ der zweiten Vernadelungseinrichtung 4 kann das Einstichbild des fertig vernadelten Vlieses 6 erheblich beeinflusst werden. Die Einstellung des Betriebsparameters "Phase des vertikalen Antriebs" in der zweiten Vernadelungseinrichtung 4 kann ohne Weiteres im laufenden Betrieb der Anlage erfolgen.Another operating parameter of the second needling device 4, which can be adapted to homogenize the stitching pattern of the needled
Ein möglicher Strukturparameter der zweiten Vernadelungseinrichtung 4, dessen Anpassung zu einer Homogenisierung des Einstichbildes des vernadelten Vlieses 6 führen kann, ist beispielsweise der Abstand der zweiten Vernadelungseinrichtung 4 zur ersten Vernadelungseinrichtung 2 in der Transportrichtung T des Vlieses 6. In
Ein weiterer Strukturparameter der zweiten Vernadelungseinrichtung 4, der erfindungsgemäß zur Homogenisierung des Einstichbildes des vernadelten Vlieses 6 angepasst werden kann, ist die seitliche Positionierung des mindestens einen Nadelbretts 14 in der zweiten Vernadelungseinrichtung 4 quer zur Transportrichtung T des Vlieses 6. Ein Beispiel für einen geeigneten Verschiebemechanismus ist in
Ein weiterer Strukturparameter der zweiten Vernadelungseinrichtung 4, dessen Anpassung zu einer Homogenisierung des Einstichbildes im vernadelten Vlies 6 führen kann, ist die Nadelanordnung im mindestens einen Nadelbrett 14 der zweiten Vernadelungseinrichtung 4. Da ein Nadelbrett sehr viele mögliche Nadelpositionen beinhaltet, bildet die Variabilität in der Nadelanordnung eine besonders effektive Variante zur Verbesserung des Einstichbildes.A further structural parameter of the second needling device 4, whose adaptation can lead to a homogenization of the stitching pattern in the needled
Eine erste Option zur Variation der Nadelanordnung im Nadelbrett 14 ist die gezielte teilweise Bestückung eines herkömmlichen Nadelbretts 14 mit Nadeln 16, die lediglich in die von der Steuereinrichtung 22 berechneten Bohrungen eingeführt werden, während andere Bohrungen des Nadelbretts 14 frei bleiben. Die gezielte teilweise Bestückung des Nadelbretts 14 kann manuell oder mittels eines Bestückungsautomaten durchgeführt werden, der von der Steuereinrichtung 22 gesteuert wird.A first option for varying the needle assembly in the
Eine weitere Option zur Variation der Nadelanordnung im Nadelbrett 14 ist eine Anordnung, bei der die Nadeln 16 im Bereich des mindestens einen Nadelbretts 14 horizontal verschiebbar sind. Zur Umsetzung dieses Prinzips existieren mehrere Möglichkeiten.Another option for varying the needle arrangement in the
Eine erste Möglichkeit ist in
Die einzelnen Nadelmodule 44 können nun in den Schlitzen 42 verschoben werden, und nach Erreichen der korrekten Schiebeposition werden die Nadelmodule 44 durch Kräfte zwischen Nadelbrett 14 und dem zugehörigen Nadelbalken 34 (
In
In seinem Endbereich weist das Trägerelement 46 einen verbreiterten Kopfabschnitt 56 auf, der in einem entsprechend verbreiterten Abschnitt des zugehörigen Schlitzes 42 verschiebbar aufgenommen und geführt ist. Vorzugsweise ist zumindest der Kopfabschnitt 56 ferromagnetisch ausgebildet. Im Einbauzustand sind die Kopfabschnitte 56 der Nadelmodule 44 dann an der Magnetplatte 52 fixiert. Zu weiteren Gestaltungsmöglichkeiten der hier verwendeten Nadelmodule 44 wird wiederum auf
Es sei hiermit darauf hingewiesen, dass Einzelheiten der in
In
Jedes Nadelmodul 44 weist einen Kopfabschnitt 56 auf, der ferromagnetisch ist. Bei abgeschalteter Magnetplatte 52 sind die Nadelmodule 44 verschiebbar bzw. können neu platziert werden, bei eingeschalteter Magnetplatte 52 sind sie an beliebiger Stelle an der Magnetplatte 52 fixiert. Zwischenräume zwischen einzelnen Nadelmodulen 44 können durch Zwischenstücke 58 überbrückt werden, um eine Stabilisierung zu erreichen. Die Zwischenstücke 58 können bevorzugt ebenfalls ferromagnetisch sein.Each
Die in
Zwischen der Magnetplatte 52 und den Nadelbrettsegmenten 54 kann zudem in horizontaler Richtung eine Klemmkraft beaufschlagt werden, beispielsweise über einen pneumatisch aktivierbaren Luftschlauch 62. Dies ist insbesondere dann notwendig, wenn manche der Nadelbrettsegmente 54 nicht magnetisch an der Magnetplatte 52 haften, weil sie beispielsweise aus Kunststoff oder Aluminium gebildet sind. Eine derartige Verspannungseinrichtung kann auch bei der Ausführungsform gemäß
Eine weitere Möglichkeit der variablen Nadelanordnung im Nadelbrett 14 liegt darin, die Nadeln 16 in mindestens einem Nadelbrett 14 vertikal zu verschieben. Ein Beispiel einer derartigen Ausgestaltung ist in
In der in
Die Fixierung der Nadeln 16 erfolgt im dargestellten Beispielsfall durch mehrere Hebel 72, die eine horizontale Kraft auf die mittlere Lage 66 des Nadelbretts 14 aufbringen und somit die durch die mittlere Lage 66 hindurch verlaufenden Nadeln 16 gegenüber der oberen Platte 64 und der unteren Platte 68 des Nadelbretts 14 verspannen. Die mittlere Lage 66 des Nadelbretts 14 kann, wie im dargestellten Beispielsfall, einstückig ausgebildet sein, oder aber auch segmentiert. Mit dieser Anordnung können einzelne Nadeln 16 in ihrer Höhenposition eingestellt und dort fixiert werden. Die einzelnen Nadeln 16 werden somit für den Eingriff in das Vlies 6 aktiviert, indem sie nach unten gezogen werden, und sie werden deaktiviert, indem sie nach oben geschoben werden. Es sind noch mehrere andere Möglichkeiten der vertikalen Verschiebung der Nadeln 16 im Nadelbrett 14 denkbar.The fixation of the
Die in
Bislang war immer nur von einer ersten Vernadelungseinrichtung 2 und einer zweiten Vernadelungseinrichtung 4 die Rede. Es ist aber selbstverständlich möglich, dass noch weitere Vernadelungseinrichtungen im Rahmen der Erfindung verwendet werden.So far, only a
Viele weitere Modifikationen und Ausgestaltungen der Details zu den Einstellmöglichkeiten des Betriebsparameters und/oder Strukturparameters der zweiten Vernadelungseinrichtung 4 sind für den Fachmann ersichtlich.Many further modifications and refinements of the details of the adjustment possibilities of the operating parameter and / or structural parameter of the second needling device 4 will be apparent to those skilled in the art.
In bestimmten Fällen kann die Einstellung nur eines der genannten Parameter ausreichend oder vorteilhaft sein, ebenso können aber im Rahmen der Erfindung auch mehrere der genannten Parameter gleichzeitig angepasst werden.In certain cases, the adjustment of only one of the mentioned parameters may be sufficient or advantageous, but in the context of the invention several of the mentioned parameters can also be adapted simultaneously.
Claims (15)
- Method for homogenising the puncture pattern in a needled non-woven fabric (6) comprising the following steps:Setting up a first needling unit (2) and a second needling unit (4) which are arranged in series wherein each needling unit (2, 4) comprises a plurality of needles (10, 16) attached to at least one movable needle board (8, 14) for needling an incoming non-woven fabric (6);needling the incoming non-woven fabric (6) in the first needling unit (2) whereby a plurality of punctures is produced in the non-woven fabric (6);detecting the faulty puncture sites in the non-woven fabric (6) in a region between the first needling unit (2) and the second needling unit (4);further needling the non-woven fabric (6), which has been needled by the first needling unit (2), in the second needling unit (4) wherein at least one operating parameter and/or at least one structure parameter of the second needling unit (4) is adapted on the basis of the results of the detection of the faulty puncture sites in the non-woven fabric (6) in such a way that during further needling of the non-woven fabric (6) in the second needling unit (4) at least some parts of the faulty puncture sites are purposefully filled up.
- Method according to claim 1 characterised in that adapting the at least one operating parameter and/or the at least one structure parameter of the second needling unit (4) is carried out by means of automatic control or regulation.
- Method according to claim 1 or 2 characterised in that the at least one operating parameter of the second needling unit (4) comprises the advance of the non-woven fabric per stroke of the at least one needle board (14).
- Method according to one of the preceding claims characterised in that the at least one operating parameter of the second needling unit (4) comp rises the phase (φ) of a vertical drive (30) of the at least one needle board (14).
- Method according to one of the preceding claims characterised in that the at least one structure parameter of the second needling unit (4) comprises the distance from the first needling unit (2) in a transport direction (T) of the non-woven fabric (6).
- Method according to one of the preceding claims characterised in that the at least one structure parameter of the second needling unit (4) comprises the lateral positioning of the at least one needle board (14) in the second needling unit (4) transversely to a transport direction (T) of the non-woven fabric (6).
- Method according to one of the preceding claims characterised in that the at least one structure parameter of the second needling unit (4) comprises the needle arrangement in at least one needle board (14).
- Method according to claim 7 characterised in that the needles (16) are displaceable horizontally in the region of the at least one needle board (14).
- Method according to claim 8 characterised in that the at least one needle board (14) comprises a base plate (41) and a plurality of needle modules (44) held on the base plate (41), each needle module having a support element (46) which is fitted with one or a number of needles (16) wherein the individual needle modules (44) are displaceable horizontally in the needle board (14).
- Method according to one of claims 7 to 9 characterised in that the second needling unit (4) has on a needle bar (34) at least one magnetic plate (52) which serves for detachably fastening needles (16), needle modules (44) and/or needle board segments (54) on the side opposite the needle tips.
- Method according to claim 7 characterised in that the needles (16) in the at least one needle board (14) are displaceable in the vertical direction.
- Method according to one of the preceding claims characterised in that the detection of faulty puncture sites in the non-woven fabric (6) is carried out by means of an opto-electronic method, preferably by means of a digital scan of the surface of the needled non-woven fabric.
- Method according to one of the preceding claims characterised in that adapting the at least one operating parameter and/or the at least one structure parameter of the second needling unit (4) is carried out with the aid of data filed in an electronic library.
- Method according to one of the preceding claims characterised in that detection of the puncture homogeneity in the needled non-woven fabric (6) is undertaken downstream of the second needling unit (4), preferably by means of an opto-electronic method.
- Method according to claim 14 characterised in that the results of the detection of the puncture homogeneity in the needled non-woven fabric (6) downstream of the second needling unit (4) are used for fine adaption of the at least one operating parameter and/or the at least one structure parameter of the second needling unit (4).
Priority Applications (6)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP14159491.1A EP2918719B1 (en) | 2014-03-13 | 2014-03-13 | Method for homogenising the puncture pattern in a needled nonwoven fabric |
EP15193801.6A EP3000923A1 (en) | 2014-03-13 | 2014-03-13 | Needleboard |
US14/640,089 US9260806B2 (en) | 2014-03-13 | 2015-03-06 | Method for homogenizing the stitching pattern in a needled fleece |
CN201510796410.6A CN105401375B (en) | 2014-03-13 | 2015-03-12 | Needle plate |
CN201510109430.1A CN104911857B (en) | 2014-03-13 | 2015-03-12 | Method for homogenizing the sewing pattern in knitted velvet article |
US14/945,705 US9567698B2 (en) | 2014-03-13 | 2015-11-19 | Needle board |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP14159491.1A EP2918719B1 (en) | 2014-03-13 | 2014-03-13 | Method for homogenising the puncture pattern in a needled nonwoven fabric |
Related Child Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP15193801.6A Division-Into EP3000923A1 (en) | 2014-03-13 | 2014-03-13 | Needleboard |
EP15193801.6A Division EP3000923A1 (en) | 2014-03-13 | 2014-03-13 | Needleboard |
Publications (2)
Publication Number | Publication Date |
---|---|
EP2918719A1 EP2918719A1 (en) | 2015-09-16 |
EP2918719B1 true EP2918719B1 (en) | 2016-09-14 |
Family
ID=50289420
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP14159491.1A Active EP2918719B1 (en) | 2014-03-13 | 2014-03-13 | Method for homogenising the puncture pattern in a needled nonwoven fabric |
EP15193801.6A Withdrawn EP3000923A1 (en) | 2014-03-13 | 2014-03-13 | Needleboard |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP15193801.6A Withdrawn EP3000923A1 (en) | 2014-03-13 | 2014-03-13 | Needleboard |
Country Status (3)
Country | Link |
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US (2) | US9260806B2 (en) |
EP (2) | EP2918719B1 (en) |
CN (2) | CN105401375B (en) |
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CN110177478B (en) | 2016-01-19 | 2022-06-17 | 耐克创新有限合伙公司 | Footwear with felt transition between materials |
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CN109137269B (en) * | 2018-10-10 | 2024-02-02 | 烟台博斯纳钢琴制造有限公司 | Pin header assembly and piano hammer pre-trimming needle machine |
DE102019100916A1 (en) | 2019-01-15 | 2020-07-16 | Adler Pelzer Holding Gmbh | Motor vehicle floor covering, luggage compartment covering or loading floor covering with textured needled carpet surface |
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2014
- 2014-03-13 EP EP14159491.1A patent/EP2918719B1/en active Active
- 2014-03-13 EP EP15193801.6A patent/EP3000923A1/en not_active Withdrawn
-
2015
- 2015-03-06 US US14/640,089 patent/US9260806B2/en active Active
- 2015-03-12 CN CN201510796410.6A patent/CN105401375B/en active Active
- 2015-03-12 CN CN201510109430.1A patent/CN104911857B/en active Active
- 2015-11-19 US US14/945,705 patent/US9567698B2/en active Active
Also Published As
Publication number | Publication date |
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CN105401375A (en) | 2016-03-16 |
CN104911857B (en) | 2017-06-06 |
EP3000923A1 (en) | 2016-03-30 |
US9567698B2 (en) | 2017-02-14 |
US20150259836A1 (en) | 2015-09-17 |
US9260806B2 (en) | 2016-02-16 |
US20160069006A1 (en) | 2016-03-10 |
CN104911857A (en) | 2015-09-16 |
CN105401375B (en) | 2018-09-25 |
EP2918719A1 (en) | 2015-09-16 |
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