Carding Machine-Wool Carding and Cotton Carding

 

The carding machine is a spinning machine that combs the previously processed spinning raw materials into a single fiber state to generate a thin layer of reticular fibers, which is then assembled into fiber strips.
The old carding instrument gave rise to the carding machine (comb boards with inclined pin teeth planted on the two boards). By the 18th century, human methods had largely given way to mechanical methods. Many advancements and innovations in various carding machines have occurred since the nineteenth century, and a variety of specific carding machines have arisen.
Carding machines are classified into two types: rotary flat carding machines and roller carding machines. The former is mostly used for carding and cotton-type chemical fibers (mid and long fibers), whilst the latter is primarily used for carding wool and other long fibers. The fundamental mechanics of most carding machines include feeding, pre-combing, primary combing, stripping, and coil formation (winding).

Wool carding machine

The machines used to card wool are generally roller carding machine. The roller carding machine gradually decomposes the fiber bundle into single fibers by repeatedly carding and stripping the fibers, and the cylinder, work roll, and stripping roll accomplish this fundamental function.

The mechanism of the carding machine and the function of each part

The carding machine is divided into three key sections: the feeding and opening section, the pre-carding section, and the main carding section.
The big cylinder has 5 work rolls and 4 depilation rollers, and the fiber bundles are thoroughly combed and blended between the large cylinder, work rolls, and depilation rollers, transitioning from bundles to single fibers. On the big cylinder, there is also a wind wheel whose job it is to extract the single fiber situated in the deep section of the needle gap of the large cylinder after carding, therefore facilitating transfer to the doffer.
A substantial carding effect exists between the huge cylinder and the doffer. The doffer slices off a portion of the fibers on the huge cylinder with a high-speed swinging knife to make a continuous fleece, then delivers it to the next carding machine for re-carding through the bridge passing machine.
The two mopping rollers’ purpose is to decrease noil. A drain bottom is also located beneath the opening roller, conveying roller, and huge cylinder, and its purpose is to decrease hair nodding.

Common defects and causes of wool carding process

• Hair grains can be caused by a discrepancy in the thickness of the mixture or too much short hair, poor raw material condition, inappropriate moisture recovery on the machine, an incorrect carding distance or sweeping arc length of the wind wheel, an unsharp needle tip, and other factors. Methods of prevention include: acceptable mixing material selection, strengthening raw material inspection, improving moisture regain, strengthening mechanical status inspection, and so on.
• Fly: During the spinning process, the number of fly on the machine, the ground, and in the air increases and accumulates as a result of improper cleaning, failure of the cotton collection device, a sharp increase in end breaks, abnormal temperature and humidity of the air conditioner, or poor air flow. In the yarn body, flying flaws form. Methods of prevention include: determining the cleaning cycle based on the cleanliness of the workshop, frequently maintaining and examining all types of cotton collection devices, such as typical spinning equipment, and doing a thorough check of the spinning speed.
• Unequal thickness faults can be caused by different types of raw materials or the same type but varying combing degrees, as well as uneven competence levels of combing technical staff. Methods of prevention include selecting appropriate raw materials, enhancing staff skill training, optimizing carding machine process parameters, and so on.
• Knots occur mostly because raw materials were not fully cleaned in the previous manufacturing process or because succeeding processes, such as spun yarns, were not thoroughly cleaned, resulting in knots in the yarn. Prevention strategies include improving raw material cleaning management and closely enforcing post-processing cleaning process requirements, among others.

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