NEEDLED PUNCH PRODUCTION LINE

NEEDLED PUNCH PRODUCTION LINE

Introduction

Main technical indicators of production line

1. Nominal amplitude:

Lapper -2500 × 4000mm

Pre needling machine -3900mm

Main needling machine -3800mm

2. Product net width: 3300mm after trimming
3. Production variety: medium to high-end needle punched non-woven

fabric

4. Manufacturing fibers: chemical fibers such as PET and PP

Specification: 1.5D~6D × 38～76mm

5. Product specification: 400-500g/㎡
6. Production capacity: carding machine output 300kg/h (≥ 4.5D chemical

fiber as raw material)

7.Control method: PLC human-machine interface, touch screen control

Needle cloth

Frequency converter

Electrical components: the first china brand: Zhejiang Zhengtai

Main bearings: Sino American joint venture Wuxi company: Torrington

Motor

8. Total installed power of the production line: approximately 260kw

Production Line Process Flow

Five stick cotton mixer

Large storage cotton machine

Main Opener

Cotton feeder

Carding machine

Lapper

Feeding machine

middle speed Pre needling machine

middle speed downward needling machine

middle speed main needling machine

High speed downward needling machine

High speed main needling machine

Hot-rolling mill

Winding machine

 

 

Production line equipment details and main technical parameters

 

1 x Five Roll Cotton Blender

This machine is suitable for mixing, loosening, and removing impurities from

various fibers, and feeding the raw materials into the cotton box of this machine

for operation

Adjustable timing automatic feeding

Feeding curtain: Wood curtain

Frame: 2000 ㎜

Cotton roller: five

Beater diameter: φ275 ㎜

Beater speed: second gear

Beater motor: 3 kw--6 poles ×2 sets

Roller: 1.5kw

Fan motor: 4kw

 

 

1 x Large storage cotton machine

This machine is suitable for mixing, loosening, and removing impurities

from various fibers. The raw materials are fed into the cotton box of this

machine for operation.

The outlet is transported by a fan.

The large warehouse is equipped with two layers of photoelectric

control, the next layer controls the roller drive of the

precision opening and loosening machine, and the previous layer

controls the transmission of the flat curtain

Feeding curtain: PVC anti-static connection leather curtain

Machine width: 1600mm

Output: ≤ 400kg/h

Uniform cotton roller: φ 260 ㎜

Cotton roller: 310r/min

Beater diameter: φ 400 ㎜

Beater speed: 300r/min

Beater motor: Y112M-4-2.2 kW × 2 units

Rolla: 1.5 kw

Nail curtain motor: 2.2 kW

Total power: 8.1kw

 

 

1 x Noil box

1. a) Machine width：1500mm
2. b) Installed on the side of the main opening machine, photoelectric linkage

with the pre-opening machine

1. c) Cyclone evenly falling cotton
2. d) Cotton clamping roller clamping cotton feeding

 

 

2 x Main Opener

 Machine width：1500mm；

 Output：100～280kg/h；

 The wall panel of the frame is made of Q235A-10mm steel plate；

 The main tin is the carding nail plate, which is covered with the roller

body, and the roller body diameter is φ460mm；

 The driving motor power of Xilin is 5.5kw, and the maximum speed of

Xilin is 800r/min；

 The feed is held by a ten-angle disc and a straight roller. The upper

roller is under spring pressure. The roller and the input curtain are

equipped with 70 type cochlear reducer by 0.75kw motor；

 Opener machine wood curtain circumference 2850mm；

 4.5# vertical independent fan transmission, fan motor 2.2kw straight

up；

 Equipped with strong magnetic suction iron impurity removal device；

 Installed capacity: 8.45kw

 

 

1 x Vibrating cotton feeder (high position)

 Machine width：2050mm

 Output：≤280kg/h；

 The wall panel of the frame is made of Q235A-8mm steel plate；

 The cotton stripping roller is φ40 round steel with 3 φ300mm casting

flanges, made of outer sheet iron, and 3 beater Angle irons are fixed on

the cylinder；

 2.2kw motor frequency conversion drive (equipped with cochlear

reducer) is used for Angle ding curtain and cotton balancing roller,

1.5kw-6 motor drive is used for cotton stripping roller and swing plate,

1.1kw-6 for high beater and 0.754-4 for cotton clamping

 The width of the cotton box is widened by 600mm；

 Volumetric quantitative vibration feeding, photoelectric control,

photoelectric linkage with the main opening；

 Installed capacity: 5.2kw.

 

 

1 x Electronic weighing hook scale instrument

 

 

1 x Single Xilin double Doffer double clutter carding machine

 

1）Scope of application; The feeding machine output molding of the banquet

cotton carding into a net, processing into basically composed of a single

fiber quantitative fiber net, transported to the next process。

2） Technical parameters: Working width: 2300mm

Production capacity: 300kg/h (assessed based on ≥ 6D grade 1 chemical

fiber)

Applicable fiber: 1.5-6D × 38～76mm

Outbound speed: ≤40m/min

Installed capacity: 28kw

3）Structural features:

a.The main body of the machine is high quality casting (HT200), which is

combined with the profile stopper after high temperature stress relief

treatment and precision machining.

b.Feed into the flat curtain for non-slip wood curtain, equipped with cotton

roller, feeding uniform and reliable；

c.Four roller feeding, diameter φ65mm, with metal detection function,

automatic stop alarm。

d.The diameter of the main tin forest is φ1230mm,

e.There are 5 sets of work rollers and stripping rollers in the main tin forest,

with a total of 5 sets of comb area, fully carding, to achieve uniform

cotton mesh;

f.Equipped with suction fan, 6 suction points, suction into the special cotton

storage bin;

g.On both sides of the maintenance platform, guardrail, protective cover

with transparent organic glass, beautiful and generous；

h.Supporting power: 28kw

Main Xilin 18.5kw, Dofu 4kw, feeding 1.5kw,

Edge suction fan 4kw；

Except for the edge suction fan, other motors are frequency conversion

speed regulation

 

 

1 x Lapping machine

1）Scope of application: Fold the fiber net output by carding machine evenly,

lay it to the required width and thickness, and transfer it to the next

process。

2）Technical parameters: net width: ≤2200mm; Outlet width: ≤3900mm

Net laying speed: ≤40m/min; Outbound speed: 1~8m/min

Network quantity: 100~1600g/㎡; Installed capacity: 11.4kw

3）Structural characteristics:

a.The main body of the frame is composed of 8mm thick Q235-A steel folding

plate structure and profile retaining；

b.The inclined curtain, flat curtain and compensation curtain are made of PVC

anti-static leather curtain, the ring curtain and the bottom curtain are made

of wood curtain rod;

c.The driving roller of each curtain is made of φ108mm seamless steel pipe,

and the shaft head is specially strengthened.

d.The reciprocating screen is controlled accurately by PLC programmable

touch screen maker in 6 sections.

e.The reciprocating mesh is driven by synchronous belt;

f.Bottom curtain electric adjustment height, adjustable height of 800mm;

g.Net laying machine with large press roll out of the net (φ300mm)；

h.Supporting power: inclined curtain 1.5kw frequency conversion speed

regulation; Ring curtain 2.2kw frequency conversion speed control;

Reciprocating 4kw frequency conversion control; Bottom curtain 3kw

frequency conversion speed regulation; Bottom curtain lifting 0.75kw×2

sets。

 

9 Gripper feeding machine 1SET

1）Scope of application: precompress the fiber net output by the mesh

laying machine and feed it into the needling area of the preneedling

machine.

2）Technical parameters: Working width: 3800mm

Feeding speed: 1 ~ 8m/min

Feeding quantity: ≤600g/㎡ (fiber cotton net)

Installed capacity: 2.2kw

3）Structural features:

a.Clamping curtain using anti-static PVC curtain;

b.The anti-static conductance cotton ring is fed into the pre-needling area to

ensure the quality of the cotton net.

c.Feeding roller diameter φ155mm, upper roller cylinder adjustment, using

roller gear drive;

d.The assembly of the whole machine is removed from the track for easy

maintenance and cleaning。

 

 

10 Middle speed Pre needling machine 1set

2． Acupuncture form: single needle plate acupuncture;

3． Working width: 3900mm;

4． Needle stroke: 60mm

5． Fabric needle form: computer irregular and disorderly fabric

needle；

6． Needle density: 4000 / m;

7． Acupuncture frequency: 100-500 times/min (no load)；

8． Cloth speed: 0.6-6m /min, feed, discharge line speed can be

independently controlled；

9． Needle plate quality: the panel is magnesium alloy plate, the pinhole

is φ1.83, the stripping plate is 12mmQ235B board, the bottom

needle plate is 12mmQ235B board, the bottom needle plate conical

mouth, the working face is electroplated；

10． The face of the needling machine is 30mm, and the face of the beam

is 25mm. All the beams need to be sandblasted and tempered.

11． The main shaft is tempered with 45# steel; Needle beam material:

Al-Mg alloy beam

12． The main bearings are Timken bearings;

13． The feed and discharge rollers are made of seamless steel tubes, and

the feed is made of guide fiber.

14． Supporting the net plate, stripping the net plate are worm gear

electric lifting, supporting the net plate special worm gear, stripping

the net plate special worm gear;

15． Needle beam belt guide, used to ensure the concentricity of needle

and needle plate;

16． Install emergency stop device, centralized refueling device;

17． Installed power: 21kw, the main motor 15kw variable frequency

speed regulation, feed roller 1.5kw with WPDS100 1:60 reducer

variable frequency speed regulation, discharge roller 1.5kw with

WPDS100 1:60 reducer variable frequency speed regulation, needle

beam lifting motor 1.5kw, peeling board lifting motor 1.5kw.

 

11 Middle speed downward needling machine 1set

3） Acupuncture form: single needle plate under acupuncture;

4） Working width: 3800mm;

5） Acupuncture stroke: 40mm;

6） Cloth needle form: computer disorderly cloth needle;

7） Needle density: 6000 / m

8） Acupuncture frequency: 100-600 times/min (no load);

9） Cloth speed: 0.6-6m /min, feed, discharge line speed adjustable;

10） Needle plate quality: magnesium aluminum alloy material

needle plate, gas locking position, aluminum alloy needle beam,

pinhole φ1.83, stripping plate is 12mmQ235B board, bottom needle

plate 12mmQ235B board, working face by electroplating;

11） The needling machine sees the wall panel 25mm, the beam

sees the face 20mm, and all the beams need to be sandblasted and

tempered；

12） The main shaft is tempered with 45# steel;

13） The main bearing adopts Torrington bearings;

14） Seamless control of the feeding and discharging rollers, flat

discharge rollers, knurling of the front roll of the discharging roller,

and lifting of the rear roll by pulling the rod;

15） Both the net plate and the net plate are electric lifting of worm

gear. The net plate is specially made with large worm gear and the

net plate is specially made with high speed worm gear.

16） The needle beam is guided to ensure the concentricity of the

needle and the needle plate；

17） Install emergency stop device and centralized refueling device;

18） Installed power: 15.5w, the main motor 11kw frequency

control, 1.5kw feed and discharge roller with WPDS100 1:60 reducer

frequency control, needle beam lifting motor 1.5kw, stripping board

lifting motor 1.5kw.

 

 

1 x Middle speed upper needling machine

18． Acupuncture form: single needle plate acupuncture;

19． Working width: 3800mm;

20． Acupuncture stroke: 40mm;

21． Cloth needle form: computer disorderly cloth needle;

22． Needle density: 6000 / m;

23． Acupuncture frequency: 100-600 times/min (no load);

24． Cloth speed: 0.6 -- 8m/min, feed and discharge line speed can be

independently controlled;

25． Needle plate quality: magnesium aluminum alloy material needle

plate, gas locking position, aluminum alloy needle beam, pinhole

φ1.83, stripping plate is 12mmQ235B board, bottom needle plate

12mmQ235B board, working face by electroplating;

26． The needling machine sees the wall panel 25mm, the beam sees the

face 20mm, and all the beams need to be sandblasted and tempered.

27． The main shaft is tempered with 45# steel;

28． The main bearing adopts Torrington bearing;

29． Feed and discharge roller seamless control, discharge flat roller, roll

knurling before the roll out, after the roll rod lifting;

30． The supporting plate and stripping plate are electric lifting of worm

gear. The supporting plate is made of large worm gear and the

stripping plate is made of high-speed worm gear.

31． Needle beam belt guide, used to ensure the concentricity of needle

and needle plate;

32． Install emergency stop device, centralized refueling device;

33． Installed power: 15.5w, the main motor 11kw frequency control,

1.5kw feed and discharge roller with WPDS100 1:60 reducer

frequency control, needle beam lifting motor 1.5kw, stripping board

lifting motor 1.5kw.

 

 

1 x High speed main needling machine

(1 down and 1 up) 1 each

2）Technical parameters: Working width: 3800mm (needle width)

Acupuncture stroke: 40mm

Needle density: 6000 / m

Acupuncture frequency: ≤1000r/min

Cloth speed: 1 ~ 8m/min

Installed capacity: 30kw×2 sets

3）Structural characteristics:

a.Single spindle, single needle plate structure;

b.The main frame of the machine is welded with high quality steel plate and

qualitatively processed at high temperature.

c.The main drive adopts the box type double crankshaft roller balancing

mechanism, and the bearing inside the large oil tank is imported originally;

d.Lubrication system adopts centralized circulation lubrication system, with

forced cooling and low pressure alarm function;

e.The spindle is made of 40Cr, which is modulated and precision machined.

f.The pusher rod is made of 38CrMoAl, after multiple heat treatment, surface

nitriding and superfine grinding.

g.The movable needle beam is made of duraluminum-alloy steel and precision

machined.

h.The needle plate is made of 14mm thick magnesium alloy plate and 4mm

thick PU plate. The computer numerical control machine is used to process

the pinholes, and the needles are arranged randomly. The pinhole

diameter is φ1.83mm, and the air bag is locked and positioned；

i.The stripping plate and supporting plate are made of 12mm thick 16Mn

material, the pinhole is treated without thorns, and the surface is plated

with chromium.

j.The output roller is chrome-plated, the pressure of the output roller is

adjusted by air pressure and the roller surface is knurled to increase the holding

force;

k.It has the function of stopping needle plate upper and lower dead center;

L.Supporting power: main motor 22kw frequency conversion speed regulation, net

motor 1.5kw frequency conversion speed regulation, net motor 1.5kw frequency

conversion speed regulation, needle beam lifting 2.2kw, strip plate lifting 1.5kw, oil

pump motor 0.37kw.

 

14、Hot-rolling mill x 1

1、Rolling mill form: vertical two high hot rolling mill；

2、Roll specification: φ402*4000mm, wall thickness of 38mm;

3、Roller material: 45# steel;

4、Roll heat treatment: The surface is plated with hard chromium

after fine grinding, and the roll needs tempering and tempering

treatment；

5、The electric heat pipe jacket is φ38*5 seamless steel pipe;

6、The wall plate frame is welded with high quality carbon steel plate.

7、The lower roll is fixed, and the upper roll is lifted manually. The

adjustment range is 0-50mm;

8、Mill line speed 1-10 m/min;

9、The main drive adopts reducer frequency conversion drive;

10、Roll surface temperature: 220℃ adjustable, surface

temperature deviation ±3℃, temperature digital display,

automatic temperature control;

11、Heating mode: electric heating, non-circulating heat conduction

oil, heating power 54kw (each roll is heated by 9 sets of 3kw

electric heating tubes)；

12、Main transmission power: 3kw

 

1 x Cloth storage machine

 

16Winding and trimming machine 1 set

1） Scope of application: nonwoven fabric edging, counting, cutting,

winding。

2） Technical parameters: winding form: double roller friction type

winding.

Coil diameter: φ1200mm

Roll diameter: φ400mm

Installed capacity: 2.2kw

3） Structural characteristics:

a.The main body of the machine adopts Q235-A steel plate and profile

combination.

b.Five longitudinal pneumatic cutters to cut.