NEEDLED PUNCH PRODUCTION LINE
Description
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
a) Machine width：1500mm
b) Installed on the side of the main opening machine, photoelectric linkage
with the pre-opening machine
c) Cyclone evenly falling cotton
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.
c.Transverse cutting with electric cutting scissors.
d.Code counting mode: pulse counting, digital display.
e.Wrap grain rubber around the surface of the take-up roll.
Electrical control part:
Huichuan frequency conversion, Chint Electric, PLC programming control,
vertical electrical control cabinet, independent touch screen operating
cabinet, synchronous start of the whole line.
Remarks
User provided:
1、All electric wires and reading outside the electric control cabinet
shall be provided by the user
2、Needling machine needling;
3、One air compressor.
4、The corresponding power facilities are about 260kw