Characters and applications of Needle loom

Characters and applications of Needle loom

 

Changhui Yang, General Manager
Shantou SANFAI Nonwoven Machinery Factory, Ltd 

 

  During the short 5 years, from an unknown little factory to get the honor of ‘a dark horse in domestic non-woven equipment manufacturing industry’, Shantou SANFAI made rapid development and was well-reputed in the nonwoven industry. It was because of insisting on the idea of considering customers and benefiting customers, as well carrying out the idea throughout all periods of design, manufacture and installation, we won these achievements. Needle loom, as our topped product with effective and applicable design, demonstrated the idea well. 


  By a long-time investigation into non-woven manufacturing industry, we took the characteristic of high tightness in non-woven machine production into account.Once lubricant leaks during production process, fiber web will be polluted. It results bad quality, even waste of raw materials. So during the production of hot products in the market these years, such as island superfine fiber synthetic imitation leather, glass fiber, filter materials, velour fiber, etc., it demands no oil leak. Push rod is the most serious oil leak part of a needle loom. Reasons are as below: as the part of linking main shaft and needle beam, reciprocations of push rod is connected with those of needle loom. When increasing needle frequency it must be operated by the way of forced lubrication to ensure work normal. It demands high tightness of the machine. One side, push rod makes strong frictions to oil seal. On the other hand, frictions between push rod and guide bushing generate a large quantity of heat, and it results lubricant rapidly heating-up which let oil seal strongly corroded. Ordinary oil seal has short useful life under double affects of physical friction and chemical corrosion, which influences production seriously. In order to solve these problems we started from bellows (as figure 1).

Figure 1:push rod& guide bushing structure 

  First, adopt high-quality oil seal to enhance abrasion resistance and corrosion resistance of the oil seal. Second, adopt push rod by high-rigidity anti-friction materials, to enhance manufacturing fineness. Surface treatment makes surface roughness down to max Ra0.8. Ensure assembling fineness strictly while assembling, to try to reduce heat of friction during working process. Third, improve the push-rod &guide-bushing heat-radiating structure, develop new lubricant circulating system with our own patent to make staying- time of the lubricant inside the guide bushing decreased. This patent of push-rod &guide-bushing heat-radiating circulating system (Patent No. ZL 2005 2 0059213.8) was applied to all of our sold machines. Heat quantity of push-rod &guide-bushing of the needle loom reduced strikingly after adopting these three measures, and it keeps surface temperature less than 45℃, enhances the tightness correspondingly. According to the investigation of our after-sale service department and feedback of our customers, total amounts of needle looms we produced domestic are near 200 units. 

 There were no oil leak accidents appear between the two closest inspection period (according to the model No., 14months ~18months) of SPN/SUN/SDN needle looms. This ensures customers produce high-quality product. We also found that large quantities of non-woven fabrics manufacture and small equipment demand the devices reliable and stable. So we enhance the reliability of the whole machine by enhancing mechanical structure and reliability of control system. Contracted structure assures high reliability. Main shaft of the needle loom is adopted by unitary crankshaft structure (patent No. ZL 2005 2 2 0059215.7 ), and push rod is driven by eccentric gear.

 Compared with machines adopted gear box transmission, this kind of structure is with shorter gearing chain and lower noise. Produced by precise equipment, advanced inspection instrument ensures high-precision installation. Adopted imported precise bearing, circle movement of the whole main shaft is controlled within 0.02mm, with steady working and little shock to the foundation. Adopted high-reliability PLC and expanded module, to control actuator accurately and ensure equipment run steadily. Reliable mechanical structure and excellent control system, make needle looms we produced continuous working in the long period. And it proves to be unworried equipment for the customers.

 Simple and convenient installation and maintenance save a large quantity of time and expenses for customers. On installation, our equipments are with little vibration, and no special requirement for foundation. Only a shockproof rubber pad will meet customers’ requirements on the ordinary foundation, which is easy to install and debug, save working hours for customers. We use dynamic balance equipment to negative the imbalance moment of force caused by crankshaft structure, and designed double-mainshaft movement structure applied on double board needle looms, which the same power supply is provided, but direction of them is opposite (figure 2). 

 


Figure 2:double main shaft structure

This structure eliminates vibration sources theoretically, keeps the original width while vastly improving the installation and stroke frequency. The whole machine adopted modular design and 85% of the parts are mutual, which is easy to maintain. There are cameras on the machine stand, fiber entrance &exit of our newly developed SVN velour needle loom (patent No. ZL 2005 2 0059214.2). It makes operators aware of conditions of inside needling working and nonwoven materials movement. 


  Considered customers, and taking usability into account firstly, this design idea make our designed machine famous of stability and reliability, low noise, little vibration, good tightness. We designed the most applicative equipment for each customer, but not just seek high-performance specification only. So we can supply the satisfied and high cost-performance equipment. For example, we have developed a superfine fiber leather production line with working width of 4m for one of our customers. Generally, feeding equipment of long working width needle looms can only be equipped with ordinary feeder (figure 3), which is with big fiber web drawing force, bad uniformity, and can’t manufacture product of low weight per square miter(<100g/m2). Product outputted from this type of feeder is not competitive for the customers.



Figure 3:ordinary feeding machine structure 
  So we overcame the problem of distortion caused by the big span of the pressing roller’s installing beam of the clamping type feeding machine, and developed clamping type feeding machine of wide width, applied it to the production of 4m width nonwoven fibers for the first time. With precise correcting device, the lattice is stable and accurate. Fiber web moves clamped by the upper and lower carbon lattice (figure 4), with little expansion and distortion, low drawing ratio, high quality. And it can also manufacture product with low weight per square meter. Development of long working width clamping type feeding machine solves the low fiber-web-feeding quality of the long working width needle device.



Figure 4: clamping feeding machine structure 

  We pay close attention to the nonwoven industry for a long-term period, and provide technology design and corollary equipment demanded by customers. At the same time, we cooperate with other related companies to develop production engineering of new-type nonwoven fibers, to realize win-win cooperation. Now we are designing long stroke needle loom producing such as ceramic fibers, glass fibers, etc. and we would like to communicate with you on these fields.


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