NL2027880B1 - Carding machine drive system, drive method and carding machine - Google Patents
Carding machine drive system, drive method and carding machine Download PDFInfo
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- NL2027880B1 NL2027880B1 NL2027880A NL2027880A NL2027880B1 NL 2027880 B1 NL2027880 B1 NL 2027880B1 NL 2027880 A NL2027880 A NL 2027880A NL 2027880 A NL2027880 A NL 2027880A NL 2027880 B1 NL2027880 B1 NL 2027880B1
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
- D01G15/00—Carding machines or accessories; Card clothing; Burr-crushing or removing arrangements associated with carding or other preliminary-treatment machines
- D01G15/02—Carding machines
- D01G15/12—Details
- D01G15/36—Driving or speed control arrangements
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- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
- D01G15/00—Carding machines or accessories; Card clothing; Burr-crushing or removing arrangements associated with carding or other preliminary-treatment machines
- D01G15/02—Carding machines
- D01G15/08—Carding machines with flats or like members or endless card sheets operating in association with a main cylinder
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- Textile Engineering (AREA)
- Preliminary Treatment Of Fibers (AREA)
Abstract
The present invention discloses a carding machine drive system, a drive method and a carding machine, including: a cylinder part drive mechanism, a flat part drive mechanism, a doffer part drive mechanism, an apron cotton guiding device drive mechanism, and a pressure roll part drive mechanism. During start acceleration and stop deceleration phases, various carding units can ensure that a fixed speed ratio remains unchanged, thereby preventing a cotton fiber from being damaged, such as stretched or extruded, during the start and stop phases of the machine. A reducer is used to drive between a flat and a cylinder, which ensures a speed requirement and also synchronization between the flat and the cylinder. The reducer can shift gears according to the requirements of different materials, which improves the operating range and economic value of the machine. At the same time, a clutch is used to greatly improve the cleaning efficiency of a movable flat. The reducer has a box structure, which has the advantages of being less susceptible to contamination of cotton and facilitating lubrication. A doffer part adopts a double-sided synchronous belt, which effectively simplifies the drive system and ensures the accuracy of a drive ratio. An apron cotton guiding device enables the machine to automatically deliver a sliver, and the quality of the delivery is greatly improved by the flexible adjustment of a pressure roll.
Description
-1- CARDING MACHINE DRIVE SYSTEM, DRIVE METHOD AND CARDING
TECHNICAL FIELD The present disclosure relates to the technical field of machinery, and in particular, to a carding machine drive system, a drive method and a carding machine.
BACKGROUND In the design of a carding machine, a drive system is a core part, which connects each part of the machine and delivers power to each part. A carding process has a high requirement on the speed of each carding work piece. A difference in the needle direction of a cooperating carding roll and a difference between the speed ratios of the carding work piece and the carding roll will have a great impact on the carding effect. In addition, as the carding machine adopts a closed structure, various carding units must ensure that their drive systems are synchronized, so as to prevent a large traffic jam and waste of a raw material. Therefore, the characteristics of the raw material put forward a high requirement on a drive ratio of the carding machine drive system, and the various carding parts need to ensure the connection of their drive, which puts a high requirement on the design of the carding machine drive system.
In recent years, with the continuous development of electrical technology and the emergence of new carding technology, the carding machine drive system has undergone a tremendous change. At present, imported carding machines mostly adopt a multi-motor drive mode, that is, each carding unit is equipped with a separate motor to drive; at the same time, for the consideration of the synchronization requirement and cost of the drive system, domestic carding machines adopt a dual-motor drive mode. Both drive modes have their own characteristics. With the rapid development of the textile industry, how to design a carding machine drive system that can meet the synchronization requirement while ensuring a cost advantage is particularly urgent, and it is a far-reaching subject to study the improved design of the carding machine drive system.
After searching, the existing carding machine drive systems in the domestic and foreign markets are reviewed as follows:
2- A domestic first-generation high-yield carding machine A186 type adopts single-motor drive, that is, one motor is used to drive.
The motor first transmits power to a cylinder, and then the cylinder transmits the power through a mechanical drive system to other carding work pieces.
A belt, a chain and a gear ensure a correct speed ratio of the various carding components of the whole machine.
When the motor is started for working, the various carding components will synchronously reach a required running speed.
This drive mode reduces the use of the motor, the input of electric equipment is low, the programming control workload is small, and the requirement on the machining accuracy of machine parts is low, so that the cost is low; meanwhile, the
IO synchronization performance of the whole machine is ensured, and in the case the machine 1s powered off, it is also possible to avoid the problem of asynchronous stop caused by a difference in cylinder inertia, thereby greatly reducing the probability of occurrence of problems such as machine blockage and waste of raw materials caused by sudden power failure.
However, the solution has the disadvantages of low drive efficiency and easy generation of heat.
The single-motor drive mode has a large drive ratio and a long drive line, which requires more drive components, thereby greatly increasing the complexity of the drive system; every additional drive link causes energy loss, thereby making the drive efficiency of the whole drive line greatly reduced; besides, the system will cause heat when it works normally, which is easy to cause malfunction.
A domestic third-generation high-yield carding machine, like the FA201 type, adopts a drive system that is mainly composed of two main motors.
On one drive line, a constant-speed motor transmits power to a cylinder, a licker-in and a flat (the flat of the third-generation high-yield carding machine is driven by a separate small motor in order that it is convenient to change the speed); on the other drive line, a variable- speed motor transmits power to a doffer, a cotton stripping roller and top and lower pressure rolls.
In addition, a safety cleaning roll needs to be driven by a small motor, which can also be used to drive a stripping roll.
This drive mode has good synchronism, high drive efficiency and stable drive.
Under the premise of ensuring linkage, it still has the advantage of good synchronism of the above-mentioned single- motor drive, but compared with the single-motor drive, the drive components are reduced, which simplifies the drive system and improves the drive efficiency and
-3- stability of the machine. The product cost is increased, and the workload of machine production, installation, operation and maintenance is greatly reduced. A DK3 type carding machine produced by a Swiss company uses three three-phase motors. The first motor is a special three-phase motor, which drives a cylinder, a licker-in and flat through a belt. The second motor is a double-contact shunt motor, which drives a cotton feeding roller by a chain. The third motor is a double-contact shunt motor, which drives a doffer, a cotton stripping roller and a coiling component. The second and the third motors have the same performance, and both are continuously variable-speed motors. The latter two motors are controlled by an electronic controller to synchronize cotton feeding and sliver delivery. When the delivery speed is changed, the multiple of drafting is always unchanged. Changing the number of slivers does not require changing a gear, which greatly reduces the workload of maintenance. The start and stop of the cylinder and the movement of the raw material are also synchronized, so there is no need to reconnect a sliver head when driving again. It can be seen from the above analysis that the domestic third-generation high-yield carding machine can basically meet the synchronization requirement, but because the flat uses a separate motor to drive, the synchronization between the flat and the cylinder cannot be guaranteed. The domestic third-generation high-yield carding machine uses single-zone flat carding (there 1s only one flat above the cylinder), and the drive system of the present invention is designed based on double-zone flat carding. For the DK3 type carding machine produced by a Swiss company, as the respective drive components are driven by a separate motor, electronic control must be used to achieve the synchronization requirement; the cost is high and the requirement on the control system is high, and the technology is currently controlled by a small number of foreign companies. At the same time, the carding machine is not a precision machine, the production precision is not high, and it is not good to use the control system like a machine tool.
SUMMARY In order to solve the deficiencies of the prior art, an embodiment of the present disclosure provides a carding machine drive system, which has a good synchronous drive effect on various carding machine units.
4- To achieve the above purpose, the present invention adopts the following technical solutions: A carding machine drive system includes: a cylinder part drive mechanism, a flat part drive mechanism, a doffer part drive mechanism, an apron cotton guiding device drive mechanism, and a pressure roll part drive mechanism, where in the cylinder part drive mechanism, a cylinder motor transmits power to a cylinder, and a double tension pulley changes the drive direction to a licker-in; in the flat part drive mechanism, the power is transmitted from the cylinder to a movable flat drive shaft by a belt; in the doffer part drive mechanism, a doffer motor transmits power to a pressure roll drive shaft through a synchronous pulley; in the pressure roll part drive mechanism, the pressure roll drive shaft transmits the power to an apron cotton guiding device, a cotton stripping roller, an upper pressure roll, a lower pressure roll and a doffer through a double-sided synchronous toothed belt; the apron cotton guiding device drive mechanism drives the apron cotton guiding device to move.
Further, the cylinder part drive mechanism includes a flat-belt drive mechanism of a cylinder spindle, a licker-in spindle and a reducer input shaft; components needing to be driven include a cylinder roll, a flat reducer input shaft, and a licker-in.
Further, the cylinder motor is installed on a main frame at a lower end of the cylinder; a motor pulley first transmits power to a big pulley of a cylinder pulley by a cylinder flat-belt through a double tension pulley and a tension pulley; the tension pulley can be adjusted up and down; the double tension pulley can be adjusted left and right, and is a double-row pulley having two functions; one is to serve as a driving pulley for driving the licker-in, and a torque is transmitted to a licker-in pulley through a licker-in flat- belt; the other is to be responsible for adjusting the tension; through a simultaneous action of two tension pulleys, the cylinder, the licker-in and the cylinder motor are linked.
Further, the cylinder pulley is a double-row pulley, but the diameter of the pulley is different; a small pulley on the cylinder pulley and a reducer pulley on a flat reducer transmit power through a flat flat-belt, and finally a torque is transmitted to a movable flat chain wheel through the flat reducer to realize a rotary motion of the movable flat.
-5- Further, the flat part drive mechanism includes a reducer, a flat drive shaft and a flat chain wheel; a movable flat is connected and fixed on a chain by a bolt; the flat chain wheel is fixed on the flat drive shaft; the reducer is disposed between the cylinder and the flat; the flat drive shaft is a shaft III, which is an output shaft after shifting in reduction; a component needing to be driven in this part is the movable flat; the reducer adopts a closed box structure; the box has a total of four shafts; the reducer input shaft is a shaft I, which is provided thereon with a slip double gear, and the gear can be engaged with a gear installed at both ends of a shaft II to realize two-speed shifting; at the same time, a middle section of the shaft II is machined into a worm, and the worm is engaged with a clutching helical gear on the shaft III to drive; when the clutching helical gear is not engaged with a clutch at a rear end, the power transmitted from a front end causes the clutch helical gear to idle on the shaft III; thus, the manual operation of the flat can be realized by a handle at the other end of the shaft III; otherwise, when the clutch helical gear is engaged with the clutch at the rear end, the power transmitted from the front end drives the shaft III to rotate, and the worm on the shaft III is engaged with the helical gear on the flat drive shaft, so that the torque is transmitted to the movable flat chain wheel, thereby finally realizing the rotary motion of the movable flat.
Further, the movement of both the slip double gear and the clutch on the shaft is realized by a shitting fork; in the reducer, the shaft I is provided with a reducer pulley, and the torque transmitted from the small pulley of the cylinder causes the shaft I to rotate; the slip double gear is also installed on the shaft I, which can be axially moved on the shaft I by a pushing action of the shifting fork, positioned by a tapered roller bearing and a shaft shoulder at both ends of the shaft; two gears that are engaged with the slip double gear are respectively installed at the two ends of the shaft II, and are connected with the shaft by a flat key; the shaft between the two gears is machined into a worm to deliver power to the reducer shaft III; this device enables two-speed shifting of the reducer.
Further, the flat is provided with a manual operation device, and a mechanical clutch is used to realize the switch between first-stage reduction and second-stage reduction of the reducer, that is, when a manual operation is performed, the clutch is disengaged,
-6- and a first-stage worm gear reducer is used to drive; otherwise, when the movable flat is working, a two-stage worm gear reducer is used to drive; the mechanical clutch is composed of a clutch gear and a clutch, and is controlled by the engagement and disengagement of teeth on the clutch gear and the clutch; the clutch gear is sleeved on the shaft III through a shaft sleeve; the clutch is connected to the shaft III through a flat key; the shifting fork can swing left and right to control the engagement and disengagement between the clutch gear and the clutch; when the two are engaged, the shaft III receives a torque transmitted from a shaft on a front end, and at this time, the reducer performs two-stage reduction; otherwise, when the two are disengaged, the clutch gear idles on the shaft III, and at this time, the reducer is a first- stage reducer driven by a handle; the clutch is limited by a limiting ball fixed on the shaft; the limiting ball can reciprocate in a radial direction of the shaft through a spring; a right end of the shaft HI is a worm which transmits power to the movable flat drive shaft.
Further, the movement of the slip double gear on the shaft is realized by a clutch fork; a shifting fork is installed on the shaft HI, and realizes the movement of the slip gear on the shaft by using the shaft III as a fulcrum; the reducer is enclosed by a box. Further, the doffer drive part refers to all parts using a doffer motor as a power supply source, including an apron cotton guiding device, a pressure roll part, a three-roller cotton stripping part and a doffer part; the drive of this part includes 4 lines; on a first line, a motor synchronous pulley installed on the doffer motor transmits power to a motor driven synchronous pulley of the motor synchronous pulley, the motor can be moved left and right on a frame to ensure the tensioning of a belt, and an apron drive synchronous pulley transmits the power to a synchronous pulley of the apron cotton guiding device; on a second line, a pressure roll drive synchronous pulley transmits the power to a lower pressure roll synchronous pulley in a pressure roll component, during which a tension pulley and a tension pulley enable tensioning and reversing; on a third line, a three-roller drive synchronous pulley transmits the power to a three-roller cotton stripping device, and a double-sided toothed belt is used to change the rotating direction of an upper pressure roll synchronous pulley, during which a tension pulley is used as a tension pulley, which can be adjusted left and right on the frame; finally, a cotton stripping roller synchronous pulley transmits the power to a doffer synchronous pulley, and a tension pulley tensions, which can be adjusted up and down on the frame.
<7- Further, the apron cotton guiding device drive mechanism includes two pairs of rotating belts with a set distance apart and turning in opposite directions; an apron is installed on an apron pulley; the apron pulley is installed on a pulley drive shaft; the pulley drive shaft is provided with a tapered roller bearing, positioned by a shaft shoulder; the tapered roller bearing is installed on a bearing seat; the bearing seat is fixed on a frame; a lower end of the pulley drive shaft is provided with a driven bevel gear; a driving bevel gear is engaged with the driven bevel gear to transmit a torque on an apron drive shaft to the pulley drive shaft, and the pulley drive shaft drives the apron to move through the apron pulley.
Further, the pressure roll part drive mechanism includes an upper pressure roll shaft and a lower pressure roll shaft, one end of the upper pressure roll shaft is installed on a swinging bearing seat, and the other end of the upper pressure roll shaft is provided with an upper pressure roll; one end of the swinging bearing seat is provided with a mandrel, and the swinging bearing seat is fixed on a box through the mandrel; when the swinging bearing seat rotates around the box, the upper pressure roll floats up and down with the swinging bearing seat; the lower pressure roll shaft is installed at a lower part of the box, and a lower pressure roll 1s installed at one end of the lower pressure roll shaft; the other end of the lower pressure roll shaft is provided with a lower pressure roll synchronous pulley; a pressure roll drive shaft transmits power to the lower pressure roll through a synchronous pulley to pull a sliver to move towards a coiler.
Further, an upper end of the swinging bearing seat is provided with a compression spring to provide a given pressure; the compression spring is provided with a compression nut for limiting.
The disclosure further provides a carding machine, including the above carding machine drive system, and using the above carding machine drive system to realize power transmission.
The disclosure further provides a drive method of a carding machine drive system, including: acylinder is linked with a licker-in, and the drive is that a cylinder motor transmits power to the cylinder, and a double tension pulley changes the drive direction to the licker-in; the cylinder transmits the power to a movable flat drive shaft through a belt, and a reducer is installed between the two;
-8- a pressure roll part, a lower pressure roll, an upper pressure roll, a cotton stripping roller and a doffer are driven by a doffer motor, and the drive is that the doffer motor transmits power to a pressure roll drive shaft through a synchronous pulley, and the pressure roll drive shaft transmits the power to an apron cotton guiding device, the cotton stripping roller, the lower pressure roll, the upper pressure roll and the doffer through a double-sided synchronous toothed belt.
Compared with the prior art, the beneficial effects of the present disclosure lie in that: The drive solution provided by the technical solution of the present disclosure has good synchronism in the drive process.
During start acceleration and stop deceleration
IO phases, various carding units can ensure that a fixed speed ratio remains unchanged, thereby preventing a cotton fiber from being damaged, such as stretched or extruded, during the start and stop phases of the machine.
A reducer is used to drive between a flat and a cylinder, which ensures a speed requirement and also synchronization between the flat and the cylinder.
The reducer can shift gears according to the requirements of different materials, which improves the operating range and economic value of the machine.
At the same time, a clutch is used to greatly improve the cleaning efficiency of a movable flat.
The reducer has a box structure, which has the advantages of being less susceptible to contamination of cotton and facilitating lubrication.
A doffer part adopts a double-sided synchronous belt, which effectively simplifies the drive system and ensures the accuracy of a drive ratio.
An apron cotton guiding device enables the machine to automatically deliver a sliver, and the quality of the delivery is greatly improved by the flexible adjustment of a pressure roll.
The solution greatly reduces the number of drive mechanisms compared with a single- motor drive solution.
The various carding units are separately equipped with a motor to drive, which greatly simplifies an original drive solution, greatly reduces the drive components of the machine, thereby reducing the volume of the whole machine, greatly reduces the energy loss of the whole machine, thereby greatly improving the energy utilization rate, and slows down the phenomenon of heat generation during the working process of the machine, thereby improving the service life of the whole machine.
-9-
BRIEF DESCRIPTION OF THE DRAWINGS The accompany drawings of the specification constituting a part of the present invention provide further understanding of the present invention. The schematic embodiments of the present invention and the description thereof are intended to be illustrative of the present invention and do not constitute an undue limitation of the present invention. FIG. 1(a) 1s a schematic diagram of whole machine parameter drive according to some embodiments of the present disclosure; FIG. 1(b) is a schematic diagram of a drive solution according to some embodiments of the present disclosure; FIG. 2 1s a schematic diagram showing drive of a cylinder part according to some embodiments of the present disclosure; FIG. 3 is a schematic diagram showing drive of a doffer part according to some embodiments of the present disclosure; FIG. 41s a schematic structural diagram of a flat reducer shifting device according to some embodiments of the present disclosure; FIG. 5(a)-FIG. 5(b) are a schematic structural diagram of a flat reducer manual operation device according to some embodiments of the present disclosure; FIG. 6 is a schematic diagram of an apron cotton guiding device according to some embodiments of the present disclosure; FIG. 7 is a schematic structural diagram of a pressure roll according to some embodiments of the present disclosure; and FIG. 8 is a schematic structural diagram of a bell mouth according to some embodiments of the present disclosure. Inthe figure, 1. pressure roll part, 2. lower pressure roll, 3. upper pressure roll, 4. cotton stripping roller, 5. doffer, 6. movable flat drive shaft, 7. cylinder, 8. flat reducer,
9. licker-in, 10. cotton feeding roller; I-1. main frame, I-2. cylinder motor, I-3. motor pulley, I-4. double tension pulley, 1-5. cylinder flat-belt, I-6. cylinder pulley, I-7. movable flat chain wheel, 1-8. flat flat-belt, 1-9. reducer pulley, 1-10. licker-in flat-belt, I-11. licker-in pulley, I-12. tension pulley; II-1. doffer motor, II-2. motor synchronous pulley, II-3. pressure roll drive shaft (4 synchronous pulleys are installed on the shaft, which are II-3a. motor driven synchronous pulley, II-3b. apron drive synchronous pulley, II-3c. three-roller drive
-10- synchronous pulley, and TI-3d. pressure roll drive synchronous pulley in order from the outside to the inside), II-4. tension pulley, TI-5. lower pressure roll synchronous pulley, IT -6. tension pulley, II-7. apron cotton guiding device synchronous pulley, 11-8. upper pressure roll synchronous pulley, 1-9. lower pressure roll synchronous pulley, 1-10.
cotton stripping roller shaft (2 synchronous pulleys are installed on the shaft, which are II-10a. doffer drive synchronous pulley and II-10b. cotton stripping roller synchronous pulley in order from the outside to the inside), II-11. tension pulley, 1-12. tension pulley, 1-13. doffer synchronous pulley; II-1. shaft I, TIT-2. slip double gear, NI-3. box, 11-4. tapered roller bearing, II-5. gear (197), 11-6. worm, III-7. gear (29T), 111-8. shaft II; IV-1. box, IV-2. shaft III, IV-3. tapered roller bearing, TV-4. clutch helical gear, TV-5. clutch, IV-6. clutch fork, IV-7. worm, IV-8. helical gear, IV-9. shifting fork; IV-10. limiting ball, IV-11. spring; V-1. apron drive shaft, V-2. driving bevel gear, V-3. driven bevel gear, V-4. pulley drive shaft, V-5. apron pulley, V-6. apron; VI-1. synchronous belt, VI-2. lower pressure roll shaft, VI-3. swinging bearing seat, VI-4. compression spring, VI-5. compression nut, VI-6. upper pressure roll, VI-7. upper pressure roll shaft, VI -8. lower pressure roll, VI-9. box; 1-1. magnet, 1-2. support plate, VI-9. box, 1-4. flat shaft, 1-5. base, 1-6. bolt, 1-7.
clamping screw, 1-8. swinging bearing seat, 1-9. adjustment sleeve, 1-10. support shaft.
DETAILED DESCRIPTION It should be noted that the following detailed description is exemplary and aims to further describe the present invention. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which the present invention pertains. It should be noted that the terms used herein are merely used for describing the specific embodiments, but is not intended to limit exemplary embodiments of the present invention. As used herein, the singular form is also intended to include the plural form unless otherwise indicated obviously in the context. Furthermore, it should be further understood that the terms "includes" and/or "including" used in this specification
-11- specify the presence of stated features, steps, operations, elements, components and/or their groups.
In a typical implementation manner of the present application, a novel carding machine drive mechanism includes: a cylinder part drive mechanism, a flat part drive mechanism, a doffer part drive mechanism, an apron cotton guiding device drive mechanism, and a pressure roll part drive mechanism.
In this embodiment, the whole machine adopts dual-motor drive (the dual motors refer to a "cylinder motor" and a "doffer motor"). As shown in FIG. 1(b), a cylinder 7 is linked with a licker-in 9, and the drive is that the cylinder motor first transmits power to the cylinder 7, and then a double tension pulley changes the drive direction to the licker-in 7; the other line is that the cylinder 7 transmits the power to a movable flat drive shaft 6 through a belt, and a reducer is installed between the two.
A pressure roll part 1, a lower pressure roll 2, an upper pressure roll 3, a cotton stripping roller 4 and a doffer 5 are driven by a variable-frequency motor (i.e. the doffer motor), and the drive is that the motor first transmits power to a pressure roll drive shaft through a synchronous pulley, and then the pressure roll drive shaft transmits the power to an apron cotton guiding device, the cotton stripping roller 4, the lower pressure roll 2, the upper pressure roll 3 and the doffer 5 through a double-sided synchronous toothed belt.
The cylinder part drive mechanism includes a flat-belt drive mechanism of a cylinder spindle, a licker-in spindle and a reducer input shaft; the cylinder spindle is integrated with a cylinder, and the cylinder spindle is integrated with a licker-in; the cylinder and the licker-in both are circular columns; the spindles are on a center line of the circular columns, and are connected to the reducer input shaft by welding; components needing to be driven in this part include a cylinder roll, the flat reducer input shaft, and the licker-in.
This drive line has a speed up to 1000 r/mm, and has a large center distance.
Chain drive does not run stably at a high speed, so a chain may not be used as a drive member.
At the same time, as the diameter of the cylinder is 1289 mm, if a gear is used to drive, the drive member will be too large.
Therefore, belt drive is more reasonable to be used in this part; it has the advantages of low running noise, stable operation, and suitability for large center-distance drive.
Since this part can have an inconstant drive ratio, in order to save cost and facilitate installation, it is finally decided to use a strong nylon flat-belt, which refers to a cylinder part drive flat-belt; the belt not only has
-12- original advantages as a belt, but also can prevent static electricity, thereby preventing a cotton wool from being adsorbed by static electricity.
In a specific embodiment, the licker-in, the cylinder, the doffer and a cotton stripping device (three-roller cotton stripping device) are all circular columns, and a center line of the circular columns has a shaft welded thereto; a drive member is installed on the shaft; double ends of a plurality of flats are respectively installed on two symmetrical chains; the chains are installed on a symmetrical chain wheel, and the chain wheel is installed on a chain wheel shaft.
In order to simplify the process of a pulley and ensure that a belt is not released, a IO pulley surface is designed to have a certain degree of curvature. A flat-belt can be closely attached to the pulley surface when it is tensioned. Here, the pulley refers to all pulleys for the cylinder part drive.
In this embodiment, as shown in FIG. 2, a cylinder motor 1-2 is installed on a main frame I-1 at a lower end of the cylinder 7; a motor pulley I-3 first transmits power to a big pulley of a cylinder pulley 1-6 by a cylinder flat-belt I-5, during which a double tension pulley 1-4 and a tension pulley I-12 are used; the tension pulley I-12 can be adjusted up and down, and has the advantage of convenient installation; the tightness of a belt can be adjusted by adjusting the position of the tension pulley; the double tension pulley I-4 can be adjusted left and right; it is a double-row pulley having two functions; one is to serve as a driving pulley for driving the licker-in, and a torque is transmitted to a licker-in pulley I-11 through a licker-in flat-belt I-10; the other is to be responsible for adjusting the tension; through a simultaneous action of two tension pulleys, the cylinder 7, the licker-in 9 (the two need to move simultaneously, maintain a certain speed, and be connected by the pulley) and the cylinder motor 1-2 are linked.
The cylinder pulley 1-6 is also a double-row pulley, but the diameter of the pulley is different; a small pulley on the cylinder pulley I-6 and a reducer pulley I-9 on a flat reducer 8 transmit power through a flat flat-belt I-8, and finally a torque is transmitted to a movable flat chain wheel I-7 through the flat reducer 8 to realize a rotary motion of the movable flat.
The flat part drive mechanism includes a flat reducer, a flat drive shaft and a flat chain wheel; a movable flat 1s connected and fixed on a chain by a bolt; the flat chain wheel is fixed on the flat drive shaft; the flat drive shaft is a shaft III IV-2, which is an output shaft after shifting in reduction; a component needing to be driven in this part is the
-13- movable flat. The cylinder has a speed of 397.5 r/min (the cylinder motor is a variable- frequency variable-speed motor), and the movable flat has a speed of 254.8 mm/min or
109.5 mm/min. The cylinder and the flat have a large speed difference, and their directions are opposite. Therefore, a reducer is required between the cylinder and the flat 1n the drive design. The reducer adopts a closed box structure; the box has a total of four shafts; the reducer input shaft is a shaft I, which is provided thereon with a slip double gear, and the gear can be engaged with a gear installed at both ends of a shaft II to realize two-speed shifting; at the same time, a middle section of the shaft IT is machined into a worm, and the worm is engaged with a clutching helical gear on the shaft III to drive; when the clutching helical gear is not engaged with a clutch at a rear end, the power transmitted from a front end causes the clutch helical gear to idle on the shaft IIT; thus, the manual operation of the flat can be realized by a handle at the other end of the shaft III, which greatly improves the efficiency of cleaning the flat. Otherwise, when the clutch helical gear is engaged with the clutch at the rear end, the power transmitted from the front end drives the shaft III to rotate, and the worm on the shaft III is engaged with the helical gear on the flat drive shaft, so that the torque is transmitted to the movable flat chain wheel, thereby finally realizing the rotary motion of the movable flat. The movement of both the slip double gear and the clutch on the shaft is realized by a shifting fork.
The slip double gear can be axially moved on the shaft I by a pushing action of the shifting fork, and be positioned by a bearing and a shoulder at both ends of the shaft I; the shifting fork uses the shaft III as a fulcrum; two gears (a small gear and a big gear) that are engaged with the slip double gear are respectively installed at the two ends of the shaft IL and are connected with the shaft II by a flat key; the small gear and the big gear are machined into a worm; this device enables two-speed shifting of the reducer. As shown in FIG. 4, in the reducer, the shaft I IIII-1 is provided with a reducer pulley 1-9, and the torque transmitted from a small pulley of the cylinder causes the shaft I I1I- 1 to rotate; the slip double gear 1-2 is also installed on the shaft I III-1, which can be axially moved on the shaft I II-1 by a pushing action of the shifting fork, and is positioned by a tapered roller bearing 111-4 and a shaft shoulder at both ends of the shaft; two gears (a gear (19T) II-5 and a gear (29T) 111-7) that are engaged with the slip double gear HI-2 are respectively installed at the two ends of the shaft II 1-8, and are connected with the shaft by a flat key; the shaft between the two gears is machined
-14- into a worm 1-6 to deliver power to the reducer shaft III; this device enables two- speed shifting of the reducer. As shown in FIG. 5(a)-FIG. 5(b), in order to facilitate manual cleaning and maintenance of the flat, it is necessary to design a manual operation device, and a mechanical clutch is used to realize the switch between first-stage reduction and second-stage reduction of the reducer; that is, when a manual operation is performed, the clutch is disengaged, and a first-stage worm gear reducer is used to drive; otherwise, when the movable flat is working, a two-stage worm gear reducer is used to drive.
A middle section of the shaft II is machined into a worm, and the worm is engaged with a clutch helical gear IV-4 on the shaft III TV-2; when the clutch helical gear IV-4 is not engaged with a clutch IV-5 at a rear end, the power transmitted from a front end causes the clutch helical gear IV-4 to idle on the shaft III IV-2; thus, the manual operation of the flat can be realized by a handle at the other end of the shaft ITI, which greatly improves the efficiency of cleaning the flat. Otherwise, when the clutch helical gear is engaged with the clutch at the rear end, the power transmitted from the front end drives the shaft III to rotate, and the worm IV-7 on the shaft III is engaged with the helical gear IV-8 on the flat drive shaft 6, so that the torque is transmitted to the movable flat chain wheel, thereby finally realizing the rotary motion of the movable flat. The movement of the slip double gear on the shaft is realized by a clutch fork IV- 6; a shifting fork IV-9 is installed on the shaft III, and realizes the movement of the slip gear on the shaft by using the shaft HI as a fulcrum; the reducer is enclosed by a box IV-1.
The mechanical clutch is composed of a clutch gear and a clutch, and is controlled by the engagement and disengagement of teeth on the clutch gear and the clutch. The clutch gear is sleeved on the shaft III through a shaft sleeve; the clutch is connected to the shaft III through a flat key; the shifting fork can swing left and right to control the engagement and disengagement between the clutch gear and the clutch; when the two are engaged, the shaft III receives a torque transmitted from a shaft on a front end, and at this time, the reducer performs two-stage reduction; otherwise, when the two are disengaged, the clutch gear idles on the shaft III, and at this time, the reducer is a first- stage reducer driven by a handle; the clutch is limited by a limiting ball TV-10 fixed on the shaft; the limiting ball can reciprocate in a radial direction of the shaft through a
-15- spring IV-11. A right end of the shaft III is a worm which transmits power to the movable flat drive shaft. The doffer part drive mechanism includes an apron cotton guiding drive part, a pressure roll drive part, a three-roller cotton stripping part and a doffer part; components needing to be driven in this part include a pressure roll drive shaft, an apron cotton guiding drive shaft, top and lower pressure rolls, a cotton stripping roller and a doffer spindle. Referring to the design of the cylinder drive part, a pulley is still used to drive, but as the speed of the doffer is affected by a sensor, the speed needs to be regulated in real time, which has a high requirement on the drive ratio. Therefore, a IO synchronous toothed belt is used to drive, which has stable operation, no slip phenomenon, and low noise. There are many moving parts on this line, and the running resistance of the machine is small. In order to simplify the drive system, a double-sided synchronous toothed belt is used, and at a three-roller cotton stripping position, the double-sided synchronous toothed belt realizes the reversing of an upper pressure roll, thereby reducing the use of tensioning.
As shown in FIG. 3, the doffer drive part refers to all parts using a doffer motor as a power supply source, including an apron cotton guiding device, a pressure roll part, a three-roller cotton stripping part and a doffer part; the drive of this part includes 4 lines (linkage, synchronous pulley and pulley); on a first line, a motor synchronous pulley II-2 installed on a doffer motor II-1 transmits power to a motor driven synchronous pulley II-3a of the motor synchronous pulley, the motor can be moved left and right on a frame to ensure the tensioning of a belt, and an apron drive synchronous pulley II-3b transmits the power to a synchronous pulley II-7 of the apron cotton guiding device; on a second line, a pressure roll drive synchronous pulley TI-3d transmits the power to a lower pressure roll synchronous pulley 11-5 in a pressure roll component, during which a tension pulley 11-4 and a tension pulley II-6 enable tensioning and reversing; on a third line, a three-roller drive synchronous pulley II-3¢ transmits the power to a three- roller cotton stripping device (an upper pressure roll synchronous pulley II-8, a lower pressure roll synchronous pulley 11-9 and a doffer drive synchronous pulley II-10a), and a double-sided toothed belt is used to change the rotating direction of the upper pressure roll synchronous pulley 11-8, during which a tension pulley II-11 is used as a tension pulley, which can be adjusted left and right on the frame. Finally, a cotton stripping roller synchronous pulley II-10b transmits the power to a doffer synchronous
-16- pulley II-13, and a tension pulley 1-12 tensions, which can be adjusted up and down on the frame. As shown in FIG. 6, a component needing to be driven in the apron cotton guiding device drive mechanism is an apron. The apron cotton guiding device gathers a cotton web stripped by a three-roller stripping device and pulls it to a pressure roller device.
The apron cotton guiding device drive mechanism is structurally composed of two pairs of rotating belts with a distance of 10 mm apart and turning in opposite directions; an apron V-6 is installed on an apron pulley V-5; a pulley drive shaft V-4 is provided with a tapered roller bearing, positioned by a shaft shoulder; a bearing seat is fixed on a frame; a lower end of the pulley drive shaft V-4 is provided with a driven bevel gear V-3; a driving bevel gear V-2 is engaged with the driven bevel gear V-3 to transmit a torque on an apron drive shaft V-1 to the pulley drive shaft. Drive components of the pressure roll part drive mechanism are top and lower pressure rolls. A pressure roll is located at the end of the machine to deliver and pull cotton, and asliver is pulled into a coiler by the pressure roll. The pressure roll is an important delivery component, and its pressure, delivery speed and pulling force directly determine the quality of the sliver and the working efficiency of the machine. An upper pressure roll of the pressure roll adopts a lever principle to slightly float up and down in a box; a lower pressure roll is driven by a synchronous pulley; the top and lower pressure rolls are matched according to a process requirement, and work together to complete a work task. As shown in FIG. 7, in an upper pressure rol! part, when the thickness of the cotton is too large, in order to prevent crushing of the cotton, an upper pressure roll VI-6 should be able to float up and down; therefore, according to a lever principle, a component equivalent to a lever is designed, that is, a swinging bearing seat VI-3; the upper pressure roll VI-6 is installed at one end of an upper pressure roll shaft VI-7; the upper pressure roll shaft 1s installed in the swinging bearing seat; the other end of the swinging bearing seat is provided with a mandrel; the swinging bearing seat is fixed on a box VI-9; when the swinging bearing seat rotates around the box, the upper pressure roll floats up and down with the swinging bearing seat; at the same time, an upper end of the swinging bearing seat is provided with a compression spring VI-4 to provide a given pressure; finally the compression spring is provided with a compression nut VI-5
-17- for limiting; a compression bolt is installed above the compression spring, and the bolt is matched with an internal thread of the box VI-9. A lower pressure roll shaft VI-2 is installed at a lower side of the box, and a lower pressure roll VI-8 is installed at one end of the lower pressure roll shaft; the other end of the lower pressure roll shaft is provided with a lower pressure roll synchronous pulley II-5; a pressure roll drive shaft transmits power to the lower pressure roll through a synchronous pulley VI-1 to pull a sliver to move towards a coiler. The upper pressure roll and the lower pressure roll have small grooves of the same width; a high step is on a right side of the small groove of the upper pressure roll, and a IO high step is on a left side of the small groove of the upper pressure roll of the lower pressure roll; the two steps act at the same time to limit the width of a sliver in a horizontal direction; at the same time, the two steps have a gap of 2 mm in a radial direction, and a sensor is disposed at this position; once a surface layer is too thick, the cotton delivery speed can be adjusted by the sensor, thereby realizing a limit on the height of the sliver. In addition to the above-mentioned pressure roll working part, the pressure roll part further includes a drive part, a bell mouth part and a box part. The drive part is mainly composed of a lower pressure roll synchronous pulley and a tension pulley; power is transmitted to the down pressure synchronous pulley through a pressure roll drive shaft; two tension pulleys are installed on a tension pulley bracket, which can be adjusted on the box and work together to realize the functions of tensioning and reversing. The bell mouth part adopts profile design and has a trumpet shape; an upper end of the bell mouth part is cylindrical, and is connected to a support by a clamping screw; a cylindrical edge at a lower end of the bell mouth part is machined with two special grooves, which are ensured to match with the top and lower pressure rolls, and an elliptical through hole is machined in the center; the function of the bell mouth is to perform a first shaping process on the sliver; the bell mouth is installed on a support plate.
As shown in FIG. 8(a)-FIG. 8(b), an upper end of a support plate 1-2 is attracted to a box by a magnet 1-1, and a lower end uses a flat shaft 1-4 to match with a flat shaft hole in a base 1-5 for fixing; the base is connected and fixed on the box by a bolt 1-6; a shaft sleeve is installed in the middle of a support shaft 1-10 to sleeve a swinging
-18- bearing seat 1-8 on the shaft; a left end of the support shaft is machined into a flat shaft, and a right end is provided with an adjustment sleeve 1-9; the support shaft is fixed to the box by a clamping screw 1-7. The box is designed to reduce the volume as much as possible, and fully enclosed design is adopted; a lower end is fixed to a bottom plate by a bolt. In this embodiment, a related calculation of the carding machine drive system is disclosed: I. important parameters of carding machine According to an experiment and experience, some parameters of the carding machine are shown in Table 1. Table 1 Parameters of important parts of carding machine Item Rotating Item Specification Speed — Remarks No. direction Diameter: 250 985 r/min Cylinder speed: 1 Licker-in Clockwise mm 1047 r/min 397 r/min . . Diameter: 1289 Î Î . 2 Big cylinder 397 t/min Anticlockwise mim / 109.4 mm/min / Cylinder speed: 3 Movable flat Quantity: 82 Clockwise
254.8 mm/min 397 r/min Diameter: 706 / Freguency 4 Doffer 10-60 t/min Clockwise mm control Cotton stripping Diameter: 119 / / Frequency 5 60-360 r/min Clockwise roller mm control / / Frequency 6 Upper pressure roll Diameter: 75 mm 110-680 t/min Clockwise control Diameter: 110 . / / Frequency 7 Lower pressure roll 70-460 r/min Anticlockwise mm control | / . Frequency 8 Big pressure roll Diameter: 72 mm 130-820 r/min Anticlockwise control Left clockwise Apron cotton . . . 9 Co / Diameter: 45 mm 120-760 r/min right guiding device / / anticlockwise II, selection of motor Working power required by a carding machine: FiV1 Fava Favy kW; P,===kW; P,;=—=kW (1 Put = a5 KW; Pua = 7060 KW: Pus = KW (1) 15 Py =P +Py2 Ps (2) In the formula, Py, P>, Py,3 and P are required working power of a cylinder, a licker-in, a flat and the three parts, respectively, kW; F,, F, and F5 are working
-19- resistance of the cylinder, the licker-in and the flat, respectively; vi, v, and v3 are the speed of the cylinder, the licker-in and the flat, respectively; P,=1.58 kW can be obtained according to formulas (1) and (2). The drive efficiency of various drive pairs looked up from a table is shown in Table 2 5S below. Table 2 Drive efficiency of main drive pairs Reng EE Womamd Drive pair bearing Cylindrical gear Belt drive pear (8 pairs) (Level § accuracy) (2 pairs) © Efficiency n,=099 n,=097 @,=0% n,=075 According to a formula (3), total drive efficiency from a cylinder motor to main moving parts is n,=0.428. =n, nny tn, (3) IO Calculation results of formulas (2) and (3) are substituted to a formula (3-4) to obtain P,=3.69. p= (4) According to output effective power, a motor of a carding machine special motor FO2 series is selected; its main performance parameters are shown in Table 3: Table 3-3 Performance parameters of FO2-72-4 type motor Molormodel | Rtedpower Synchronous Fullload speed starting power maximum power (kW) speed (r/min) (t/min) rated power rated power OO FO2724 43006020 TIL determination and distribution of total drive ratio of drive device (1) Cylinder part: according to Table 3-1, the speed of a cylinder is 397 r/min, and according to Table 3-2, the speed of the motor is 1460 r/min. Therefore, the drive ratio between the cylinder and the motor is 3.67. (2) Licker-in part: the speed of a licker-in is 985 r/min and 1047 r/min, and the speed of the motor is 1460 r/min, so the drive ratio between the licker-in and the motor is
1.48 and 1.39. As the licker-in and the motor rotate in opposite directions, according to Chapter 2, the motor first transmits power to a tension pulley, and then to the licker-in, so there are two drive ratios between the licker-in and the motor, that is, 1,=0.67, 1,1=2.22 and iy; = 2.09.
-20- (3) Movable flat part: the speed of a flat is 109.4 mm/min and 254.8 mm/min; the speed of the cylinder is 397 r/min; a chain wheel on a drive shaft makes the movable flat move circularly; the drive ratio of the chain wheel is 13, and according to the specification of the flat, the parameters of the chain wheel are determined as Z=14 and P=36.5. Therefore, the total drive ratio i between the cylinder and a flat drive shaft is 796.6 or 1856.6, and there are two drive ratios, that is, 1, from a belt to a reducer, and 1,, from the reducer to the flat drive shaft; the reducer is a two-stage worm gear shift reducer; 1, includes a drive ratio 15; or = from a shaft I to a shaft II, or a drive ratio 15, from the shaft II to a shaft II, and a drive ratio 1,3 from the shaft III to the flat drive shaft, that is, 1,=1211551;3. In order to facilitate manufacturing, the drive ratios of the two stages of worm gears are set to be the same.
Thus, i,=151i5,7, and the total drive ratio is i=ijb jb? Since the speed change of the movable flat is completed by a slip gear of the shafts I and II, it is concluded that:
iy,’ = 21.526 (5)
i1i52°=1216.6 (6)
It 1s known that the drive ratio of belt drive 1s generally in the range of 2-4; then let 1,=2, which is substituted into a formula (6) to obtain 1,,=24.6. It can be seen from a table that a nominal drive ratio is 25, but due to a large error, it needs to be corrected.
It is stipulated that a relative deviation between an actual drive ratio and a nominal drive ratio of a two-stage reducer is A;<4%. Through a check calculation, it can be seen that the drive ratio of a worm is changed to i,,=26, and the error is small when 1,=1.8. IV, parameters of main drive shafts
The drive ratio is distributed above, and by the drive ratio, the speed, input power, output power and torque of main drive shafts can be calculated, as shown in Table 4.
21- Table 4 Movement parameters of main drive shafts Power P (kW) Torque (Nem) Speed Shaft No. eee Input Output Input Output (min) Motor shaft 4 3.8 26.16 24.86 1460 Cylinder shaft 3.65 3.58 87.69 86.01 397.5 Tension
3.65 3.58 15.92 15.61 2190 pulley shaft Licker-in
3.43 3.36 33.25: 31.29 32.58; 30.65 985; 1047 shaft Reducer shaft | 3.43 3.36 148.35 145.33 220.8 Reducer shaft 215.16: 211.20:
3.26 3.20 144.7; 337 II 89.01 90.68 Reducer shaft 4114.90;
2.4 2.35 4029: 1732 5.57; 12.96 1m 1768 Flat drive 78542; 76757,
1.76 1.72 0.214; 0.498 shaft 33751 32984 V. calculation of belt drive The cylinder, a reducer input end and the licker-in are all realized by a flat-belt. Taking the cylinder as an example, the design and calculation of belt drive between the motor and the cylinder are as follows: For the drive between the motor and the cylinder, it is known that the output power of the cylinder motor is P=3.8KW; the speed of the motor is n;=1460 r/min, and the speed of the cylinder is 397.5 r/min; the center distance is a=813 mm; the drive ratio is
3.67. The diameter of a small pulley is d;=150 mm according to a formula (7), 3jp d,=(1100-1300) I= (7) 1 The drive ratio is 3.67<i,,,=10, and the drive is satisfactory; an elastic slip factor €=0.02 is substituted into a formula (8) to obtain the diameter of a big pulley d,=540 mm; d;=id (1-€) (8) A belt speed v=11.46m/s<v,,,,=30 m/s is obtained according to a formula (9), and the belt speed is satisfactory; mdm VT 50x1000 ©)
A belt length L=2756 mm is obtained according to a formula (10), and a belt thickness is 0=1.2xn=4.8; L=2art 2 dy rp) + 2 (10) A formula (11) is solved to obtain a wrap angle of the small pulley 6,=179.5, which 1s greater than 150 degrees and is satisfactory; the number of bends is u= S6, which is appropriate; 0,=180- 2 (11) K4=1.2 is selected, and it can be seen that P;=K, <P=4.56KW; Ky=1, K;=l1 and Py=2.6 are substituted into a formula (12) to obtain a cross-sectional area of a belt, a=1.75; a belt breadth is b="2==400 mm, and a normal tension stress is co=1.8N/mm?; A= oe (12) An effective circle force is calculated according to a formula (13), F=398 N; F-2 (13) A force acting on the shaft is calculated according to a formula (14), F,=6.3N; finally, a pulley breadth is determined as B=450 mm.
F‚=209A sin (14) Similarly, the belt drive of the other parts can be calculated and designed.
It is known that the output power of a cylinder shaft and a tension pulley shaft is P=3.58 K; the speed of the cylinder shaft and the tension pulley shaft is n;=397.5 r/min, n;=2190 r/min respectively; the speed of a reducer shaft I and a licker-in shaft is 220.8 r/min, 985 or 1047 r/min respectively; a center distance is a=588 mm, 510 mm respectively; the drive ratio is 1.8, 2.22 or 2.09 respectively.
Specific calculation parameters are shown in Table 5: Table 5 Belt drive parameters of cylinder part Te Fromeylindertoreducer From cylinder tension pulley input end to licker-in Diameter of small pulley d, 100 100 Drive ratio i 18 2.22 or 2.09 Diameter of big pulley d, 180 222 or 209 Belt speed v 2.08 11.46
End belt length L 1619 1534 Belt thickness ò 4.8 4.8 Wrap angle of small pulley pats pe 179.8 179.7 & Cross-sectional area of belt
1.65 1.65
A Belt breadth b 300 300 Effective circle force F 2067 375.2 Force acting on shaft F,. 6 6 Pulley breadth B 400 400 VI, design of two-stage worm gear reducer (1) Design of shifting slip gear. The reducer has two design speeds. In the above structural design, it is determined to use a slip gear to shift and change the speed. The design and calculation of the slip gear are as follows.
As the gear needs to slip on the shaft, in order to facilitate the operation and the engagement of the gear, a straight spur gear is used to drive, which has a pressure angle of 20 ; according to a table, level 8 accuracy is used, and the material and number of teeth of a driving gear and a driven gear are shown in Table 6 below. Table 6 Gear material and number of teeth Heat treatment Number of Material Hardness method teeth selected Driving gear 40 Cr / HB,=280HBS z1=19 refining Thermal HB,= 240 Driven gear 45 7,=29 refining HBS Ze=189.8Mpa!/?, T;=9.55x 10° P/n;=1.48x 10°N-mm, 24=1; Z4=2.5;K4;=1.3, and by calculation by a formula (15), a,,=31.77, * 0, =arccos[z; cos a/(z;+2h, ) (15) 0,2=28.47, and it is substituted into a formula (16) to obtain g,=1.596; zy {tan a, -tano +z tan C,42- tan od}, e=! {tangy Lal 42 )| (16) A coefficient of contact for contact fatigue strength 1s calculated by a formula (17) to be Z,=0.895; Onim1=600 mpa, Ogtim2=550 mpa; 4- z= [= (17) The number of stress cycles is calculated according to formulas (18) and (19) to be N,=4.17x10%
24. N,=60n,jL;, (18) N;= (19) Kan, =0.9; Ky, =0.95; a probability of failure is 1.00%; S=1; they are substituted into a formula (20) to obtain [og ],=540 mpa and [o4],=523 Mpa; [og], > [Sg], so[og]=[og],=523 Mpa. [ow], =~ (20) Finally, the above coefficients are substituted into a formula (21) to obtain a reference diameter of the driving gear as d;;=73.65. A circumferential speed is calculated by a formula (22) as v=0.85 m/s. vn (22) A tooth breadth is calculated by a formula (23) as b=73.65. b=2gd, (23) According to a table, K,=1; according to v=0.8m/s and level 8 accuracy, K,=1; a circle force of the gear is calculated by a formula (24); F;;=4.019x10°N (24) It is found that Ky;,=1.2; by a difference method, Kgg=1.352, an actual load coefficient is calculated by a formula (25) to be K=1.62; Ku =KK Kg Ky (25) A reference diameter and a module of gear are calculated as d;=79.256 mm and m=4.17 mm by formulas (26) and (27) based on the actual load coefficient. drei (26) m=2! (27) It 1s selected that Kg=1.3; the coefficient of contact is calculated by a formula (28) to be Y,=0.720; Y.=0.25+ > (28) According to a diagram, òrtm1=500 mPa; ôfim2=380 mpa; Key1=0.85, Key2=0.88; S=1.4, and [og],=303.57 Mpa and [o],=238.86 Mpa are calculated by a formula (29);
25. Yia=2.87;Yi=2.5 Ysa = 1.54, Ypgp=1.62; 22200146 and “E2582 —0 0174 are {orl [oel calculated, and compared to select a bigger value, that is, T= TRE 0.0174; finally, a module is calculated by a formula (30) to be m=2.372 mm.
[op], =S: (29) mz BL ie) (30) A circumferential speed is calculated by a formula (22) to be v=0.521 m/s, a tooth breadth is calculated by a formula (23) to be b=45.068 mm, and it is calculated by a formula (31) that : =8.44.
h=(2h"+c")m, (31) Based on v=0.521 m/s and level 8 accuracy, it can be found that K=1.08: K¢,=1; it is calculated by an interpolation method that Ky;3=1.355, and in combination with
28.44, it is found that Kgz=1.432; the value is substituted into a formula (32) to obtain Kp=1.547; the module of gear is calculated by a formula (33).
Kr=KAKyKrgKrg (32) mem, EE (33) The calculation results are compared; the module is calculated as m=2.58 from a bending strength, which is rounded to be m=3; the number of teeth of the driving gear is calculated to be z;=18.97 based on d;=56.923 mm, rounded to be z;=19; the number of teeth of the driven gear is z,=1z;=1.53*19=29.07, rounded to be z,=29.
Geometric parameters of the gear are calculated. (1) Reference diameter d,=z;m=57 mm; d,=87 mm; (2) center distance a= we 7 mm; (3) gear breadth b=2d;=57 mm; as there is an error in installation, b=65, so that the tooth breadth of the big gear is equal to a designed tooth breadth.
Gear surface contact fatigue strength is checked. Parameters in a formula (34) are Ky=191; T;=4.5x1024=1; d,= 57; u=29/19; Zy=2.36; Ze=189.8:Z,=0.91, respectively; they are substituted to the formula to obtain o4=534<[og], indicating that the strength is satisfactory.
n= Ez Ze Z [on] (34)
26- Gear root endurance bending strength is checked.
Parameters in formulas (35) and (36) are Kp=1.85; T,;=4.5%10%; Yg,;=2.11; Y1=1.85; Y.=0.74; Y5,,=2.05; Yp=1.93:94=1; Z,=19, respectively, m=3, and they are substituted to the formula to obtain op =150, op, =162, indicating that the strength is satisfactory. opi EE <[ oF] (35) 0p Ez <[OF] (36) (2) Design of cylindrical worm and helical gear Worm and helical gear drive is not common drive.
According to a reference [18], the design method adopts a matching method.
In order to meet an engagement condition, the module of a helical gear is selected.
When a hob is used to machine the helical gear, a spiral angle of the helical gear should be the same as a lead angle of a worm.
When the worm is machined, an axial module should be the same as a module of the helical gear.
According to Table 3-3, input power P=3.26 kw; worm speed n;=144. 7 r/min; drive ratio i=26. The basic parameters of the helical gear and the worm are shown in Table 7 below.
Table 7 Basic parameters of helical gear and worm ~ Toothtypc Module Numberofteeth Pressurcangle Material Worm ZA m,=3.004 | (number of 20 20 threads) Helical Involute m=3 26 20 45 gear An engagement condition is that the spiral angle B of the helical gear is the same as the lead angle y of the worm, so it is calculated by a formula (37) that B=y=2.86°. cos B= cos y= = (37) Itis calculated by a formula (38) that the reference diameter of the gear is d=78 mm. dy=z—% (38) It is calculated by a formula (39) that the reference diameter of the worm is d=60 mm. dy= — (39) The center distance is calculated by a formula (40) to be a=69 mm. a=0.5(d;+d;) (40) Geometric parameters of the worm (see Table 8) and the helical gear (see Table 9) are calculated.
-27- Table 8 Parameters of worm Parameter name Formula Calculation result Axial distance P,=mm 9.42 Diametral quotient g=< 20 m Tip circle diameter dy =d;+2hm 66 Tooth root circle diameter dp=dy-2(hymc) 53 Zz Reference circle lead angle an, 2.86° Axial tooth thickness of worm S= 2 mn 4.71 Normal tooth thickness of Sp=S, COSY 4.704 worm Table 9 Parameters of helical gear Parameter name Formula Calculation result Spiral angle B 2.86 Reference diameter d=z my 78 1 LL cos B Gear breadth b=24dy, 40 A root endurance bending strength of the worm is checked. In a formula (41), Yra2=2.38, Y3=0.9192; op=56Mpa<[oc¢]; the check calculation shows that the bending strength is satisfactory.
1.53KT, == ——— . < OF am Ya YgSLor] (41) A surface contact fatigue strength of the helical gear is checked. Parameters in a formula (42) areKy=2.23; T;=9: 10%, 24=1; d,= 78; u=26; Zy=2.45, Z5=189.8; Z;=0.64,Z4=0.99 respectively; they are substituted to the formula to obtain oy=534<[oy], and the check calculation indicates that the strength is satisfactory.
ET On” en Tr Za Ze Ze Zy S[on] (42) “dl u A root endurance bending strength of the helical gear is checked. Parameters in formulas (42) and (43) are Kp=2.07; T;=9%10%; Yg,;=2.50; Y¢,;=1.65; Y,=0.68; Yr,2=2.18; Yn=1.79; @4=1; Z,=1, respectively; m=3; they are substituted to the formula to obtain op1=150 mpa, op,=162Mpa, indicating that the strength is satisfactory. KET) Yi, Yeu Ye cos? 8 =P lh se 2 Po pl Pa <[cF] (43)
_28- 2KpT; Yea Year Ye cos? 8 EE oF] (44 OF? oq Zi? <[oF] (44) Worm and gear drive on a shaft IT can be designed by using the same method, and the parameters are consistent with the above calculation. VIL calculation of doffer drive parts It can be seen from the structural design that synchronous belt drive is adopted in this part. The same as the above design and calculation, a motor is selected first, and then synchronous pulley drive is designed and calculated. (1) Parameters of a doffer motor are shown in Table 10. Table 10 Performance parameters of Y100L-4 type motor Rated power ~~ Synchronous Full-load speed starting power maximum power Motor model —— kW) speed (r/min) (¢/min) rated power rated power Y100L-4 2.2 1500 1420 2.5 2 (2) Distribution of drive ratio Doffer motor and pressure roll drive shaft: 1,=2.57; pressure roll drive shaft and lower pressure roll: 1,=0.824; pressure roll drive shaft and cotton stripping roller: 13=1.93; pressure roll drive shaft and upper pressure roll: 13=1; pressure roll drive shaft and lower pressure roll: i4=1.47; cotton stripping roller and doffer: is = 6.13. (3) Parameters of main drive shafts are shown in Table 11. Table 11 Movement parameters of main drive shafts Shaft No. Power P (kW) Torque (Nem) Speed Input Output Input Output {t/min) Doffer motor shaft 22 2 14.80 13.45 1420 Pressure roll drive
1.92 1.88 33.21 32.51 552.2 shaft Lower pressure .
1.80 1.76 37.80 36.96 460.2 roll shaft Apron drive shaft 1.80 1.75 42.52 41.34 409.1 Apron pulley shaft 1.70 1.67 50.20 49.32 5114 Cotton stripping
1.80 169 60.19 56.5 295.8 roller shaft Upper pressure PRETP 1.80 1.69 31.13 29.22 552.2 roll shaft Lower pressure 3
1.80 1.69 45.66 42.87 376.5 roll shaft Doffer shaft 1.64 1.61 336.09 329.95 482
-29- (4) Design and calculation of synchronous pulley: Take the design of a synchronous pulley from a motor to a pressure roll drive shaft as an example.
According to a reference [17], rated power of the motor is P=2.2kW, a rated speed is n;=1420 r/min, drive ratio is 1=7/18, and the motor works in two shifts for 10 years and 200 days a year.
According to Table 3-2-41, K4=1.4, which is substituted to (37) to obtain design power P4=3.08kW; P,=K,P (37) According to P4=4 kW, n;=1420 r/min, and it is determined to be H type based on FIG. 3-2-9, with a pitch P,=12.7mm; According to the belt type H and the speed of a small pulley n;, z;=14 is selected from Table 3-2-42; in a formula (38), d;=56.60 mm; according to Table 3-2-48, an external diameter is d,;=55.23 mm; d=" (38) According to a formula (39), z,=36; z=" (39) According to a formula (40), d,=145.60 mm, and according to Table 3-2-48, dp=144.16 mm; d;=2 (40) According to a formula (41), the belt speed is v=4.2 m/s; v= (41) An initial shaft distance is a4=300 mm; according to a formula (42), L,=943.8 mm; according to Table 3-2-38, for an H-type synchronous belt with a length code of 370, a pitch line has a length of Lp=933.45 mm, and the number of teeth on the pitch line is z=72: Ly=209+ > (dy+dy)+ HA (42) According to a formula (43), an actual shaft distance is 0=310 mm; a= (43) According to a formula (44), the number of engaged teeth of the small pulley is z,=0; zien (2-2, )] (44)
-30- According to Table 3-2-44, T,=2100 N, and m=0.488 kg/m, which are substituted to (45) to obtain Py=2.09kW:; T, -mv2) p= (45 oon 9) According to Table 3-2-43, the parameters of the H-type belt are b,,=76.2 mm, z,,=8, and K,=1, which are substituted to (46) to obtain b,=24.8 mm; according to Table 3- 2-39, an H-type belt with a breadth code of 125 should be selected, where b4=25.8 mm.
Lu | Py i by=byo KpPy (46) The basic parameters of a pulley with a 370H125 synchronous belt selected to drive are shown in Table 12 below.
Table 12 Parameters of pulley Name of pulley Number of teeth z Pitch diameter d/mm External diameter d,/mm Small pulley 14 56.60 55.23 Big pulley 36 145.60 144.16 Design parameters of main synchronous pulleys are shown in Table 13. Table 13 Parameters of synchronous pulleys Pulley Drive Pulley Pitch Belt Name of pulley teeth i Belt type part type diameter breadth number Motor pulley H 14 12.7 Doffer motor to pressure roll 170 370- drive shaft Pressure roll drive 125 H 36 12.7 HI25 shaft pulley Pressure roll drive M 32 5 Pressure roll drive shaft to shaft pulley apron cotton guiding device Apron cotton 3 drive shaft 150 15 rive sha idi ice drive guiding device drive M 26 5 SM-15 shaft pulley Pressure roll drive shaft to Driving pulley H 17 12.7 270- 100 pressure roll Driven pulley H 14 12.7 HI100 Driving pulley H 15 12.7 Cotton stripping Pressure roll drive shaft to H 29 12.7 roller shaft pulley three-roller cotton stripping 540- / Upper pressure roll device H 13 12.7 HI00 100 shaft pulley
31- Lower pressure rol! H 22 12.7 shaft pulley Cotton stripping roller shaft Driving pullev H 15 12.7 620 to doffer shaft - 125 Driven pulley H 92 12.7 HIZS To sum up, the drive system of the whole machine includes a cylinder drive part and a doffer drive part. The parameters of each part are calculated above. FIG. 1(a) shows a drive structure and parameters of each drive part of the whole machine. Eighth, calculation of spring In order to prevent a material from being damaged by pressing, in structural design, an upper end of a pressure roll swings up and down by installing a compression spring. Known calculation conditions are shown in Table 14. Spring ends are tightened and ground flat, and the support circle is 1 circle. Table 14 Known quantities for design and calculation of spring Minimum Maximum External Parameter . . Working / Spring Spring working working load diameter of | name stroke h / class material load P; Pm spring Ds Parameter ‚6 Carbon spring 200N 400N Smm 25mm N=10"-10" . value wire D grade Spring stiffness is calculated by a formula (47) as P =40N/mm.
PP P= L (47) A working limit load is calculated by a formula (48) as P;=668N, and series parameter are looked up from Table 3-15 based on D,; P;>1.67P (48) Table 15 Calculation of compression spring Parameter Material Mean diameter Working limit Single-coil Single-coil name diameterd of coil D loadP; deformation/; stiffnessPg Parameter 3 4 mm 21 mm 679.34 N 2.861 mm 237 N/mm value The calculation of other spring parameters is shown in Table 16. Table 16 Calculation of other parameters Item Unit Formula Result Number of effective coils n Coil Py 6 n= p Number of total coils n; Coil n;=n+l 7
-32- Spring stiffness P N/mm p= Py 39.5 u n Deformation min F=ní; 17 under working limit load F; Pitch t min Fj 6.83 t=—+d n Free height Hy min Hy=nt+1.5d 49 External diameter of spring mn D,=D+d 25 Dy Internal diameter of spring min D;=D-d 17 D; i anole © t 3 Spiral angle a €} OATH er 5.91 nD Expansion length L mm Lw Dn, 464 cosa Check calculation of the spring is shown in Table 17. Table 17 Check calculation of spring Item Unit Calculation formula Result Height at minimum load mm Py 43.94 H=H--
P Height at maximum load mm Pu 38.87 Hp=Hyp-—
P Height at limit load P; 31.80 eight at mit 10a mm Hy=H-—
P Actual working stroke mm h=H;-H; 12.14 Range of work arca hogafe=g3s 7 =0.3:32=0.33 ipht-diameter rati H Height-diameter ratio p= 10-033
D The foregoing is merely illustrative of the preferred embodiments of the present invention and is not intended to limit the present invention, and various changes and 5 modifications may be made by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and scope of the present invention should be included within the protection scope of the present invention.
Claims (10)
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