The most detailed knowledge of setting machines
The setting workshop is an important part of the printing and dyeing factory. The level of processing directly affects the cleanliness, width and stability of the fabric surface, and post-finishing processing is the main channel to increase the value of the fabric.
◀The purpose and principle of the setting machine▶
Purpose: To improve the feel, slip, color, width, strength, appearance, etc. of the fabric by padding various dyeing materials for softness, stiffness, anti-skid, tenter and resin finishing. For non-pure cotton Variety can also play a role in stabilizing size.
Principle: The cloth is dipped in chemical materials in the trough, and is evenly pressed by the roller before entering the oven. When the cloth passes through the oven, it will be dried and shaped under the action of high-temperature hot air. The shaped cloth will have a good feel and stable size.
1 Structural characteristics of the setting machine and the functions of each unit
The setting machine mainly consists of five parts, including the feeding part, weft straightener, chain, oven body and cloth dropping and rolling device. There are also chemical systems and oil furnace heating systems.
1. Feeding part.
The structure is relatively simple, consisting of a trough and a roller. The cloth enters the trough, brings chemical materials with it, and then squeezes out the excess chemical materials through the rollers. Therefore, the chemical materials on the cloth are very uniform, which is a prerequisite for obtaining high-quality styling cloth.
What should be noted here is to always pay attention to whether the pressure on the left and right sides of the roller is consistent. Otherwise, the side with low pressure will load more material, and the side with high pressure will load more material. If it is less, the cloth will have quality problems such as left and right inconsistency.
2. Weft straightener.
The weft straightener currently configured on the setting machine is the Mahlo RFMC94H photoelectric weft straightener. There are four sets of sensors on the Mahlo photoelectric weft straightener. Each set of sensors includes luminescence and photosensitivity. In two parts, the weft and inclination of the cloth can be obtained through the photoelectric effect. The action part uses a hydraulic system. When the signal of the weft skew is transmitted back to the control main board, the control main board will issue an instruction to drive the hydraulic system to make the curved roller or straight roller adjust the corresponding angle, thereby correcting the weft skew. Specifically: when there is a difference between the center of the cloth and both sides, the curved roller will move; and when there is a difference between the left and right sides, the straight roller will move.
3. Chain part.
The tenting of the cloth on the setting machine is produced by the chain. The chain of the setting machine is driven by a high-power motor close to the cloth dropping place. The chain is equipped with a needle plate. When the cloth enters the chain, the brush wheel on the cloth pressing wheel presses the cloth on the small needle on the needle plate, and the cloth is ready. It enters the oven driven by two rows of chains. The chain of this setting machine is different from other setting machines. It can control the stretching of each section of the needle clip separately to achieve good results. However, some setting machines cannot adjust each section of the needle clip and can only adjust it to Rectangle or trapezoid.
4. Oven body.
The setting machine has eight sets of ovens. Under the blowing effect of the circulating fan (2), the air is continuously sprayed on the cloth surface from the pores on the star-shaped air jet frame. After the hot air contacts the wet cloth, the temperature drops and the humidity rises, and is discharged from the large hole on the star-shaped air jet frame, passes through the filter (6), and then is heated by the heat exchanger and continuously recycled. The heat exchanger (8) is located below the filter (6), and the hot coal used is hot oil. The heat exchanger has many thin radiating fins to produce efficient heat exchange.
5. Cloth dropping and rolling device.
The setting machine can adopt two cloth discharging methods: left and right cloth type or roll cloth type according to production needs. Both methods are driven by a motor and chain transmission. When the cloth is rolled out, the tension stability of the cloth is required to be high, and the cloth needs to pass through a tension-adjusting guide roller controlled by an air pump. With left-and-right drop cloth, the cloth does not need to pass through the tension adjustment roller but instead passes through a fixed guide roller.
◀definiteFor fluorescent cloth, 0.1% sodium hypochlorite solution should be used to wipe each guide roller of the machine and the machine should be washed with a special guide cloth liquid for more than two times;
5) Processing process Pay attention to adjusting the weft skew, door width, and dropping the fabric into the roll.
14. Latitude and skew control scheme
Later in latitude and skew When sorting out the first few items of internal and external rework, it is important to control the weft and skew. First of all, let employees know the control standards for weft skew. The control standards for weft skew in finished products are:
1) Solid color cloth and striped cloth:
Full width: 3.5% (about 5.0CM for 58.5 fabric width, about 3.5CM for 44.5 fabric width)
Half width: 4.0% (for 58.5 fabric width) Approximately equivalent to 3.0CM, 44.5 cloth width is approximately 2.2CM)
2) Plaid cloth:
Full width: 1.5% ( For 58.5 cloth width, it is approximately equivalent to 2.2CM, and for 44.5 cloth width, it is approximately 1.7CM)
Half width: 2.0% (for 58.5 cloth width, it is approximately equivalent to 1.5CM, and 44.5 cloth width is approximately 1.1CM)
Partial weft bias: no more than 4% within 20CM of the selvedge, that is, no more than 0.8CM
15. Fish scale wrinkle control plan
General high-density fabrics such as OC type shaping processing, if the moisture content of the cloth surface is not enough, in During the pre-shrinking process, it is easy to produce fish scale wrinkles, which will lead to internal and external repairs. During the shaping process, the moisture content of the dropped cloth is set (generally the moisture content is set to 12-14%) to control the moisture on the cloth surface to facilitate post-process processing.
16. Regarding the control of the final drop width
1. Inspection Is the mercerizing falling width normal?
2. Refer to the processing conditions of the same specifications or PPO varieties.
3. Quickly make the cloth to be finalized Test
4. Check the processing status of the post-process to confirm whether the shape should be wide or narrow
17. Shaping should be done on wide varieties
1. Shaped varieties with moisture
2. Post-processing Varieties with calendering
3. Varieties with special finishing
4. Varieties that will stretch a lot during pre-shrinking
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5. “D” and “CDF” varieties generally have wider widths
18. Shaping should be done in wide and narrow varieties
1. Oxford weave and square weave varieties
2. Pre-shrunk Varieties with a large shrinkage rate
3. For varieties with large shrinkage in the weft direction, the preshrunk should be as narrow as possible. When appropriate, the needle eye can be moved to the side to take into account Shrunk and finished width.
[Main fabric defects and causes]
1) Bad edge: The edge of the fabric breaks away from the needle chain, close the automatic stop of edge removal, slow down and press the fabric into the needle chain.
2) Weft skew: Adjust the weft preset twill weave, and you can use the preset twill in the opposite direction to the grain.
3) Wrinkling: Generally, increase the fabric feeding tension when edge wrinkles appear, and reduce the fabric feeding tension when longitudinal straight wrinkles appear; for loose tissue and reworked fabrics with soft body and other characteristics , the adjustable trough material surface should be as low as possible. The second step is to make the cloth smooth and enter the pressure roller
4) Stains, oil stains, rust stains: check the source and clean.
5) Weft shift: If it is caused by the overfeeding wheel, the rotation speed will be slowed down, and if it is caused by the edge suction device, it will push up the edge suction clamp.
6) Wind mark: Slight irregular indentations are formed on the cloth surface, and part of the oven is closed to allow the cloth to fall with moisture
7) Material stains: Materials react or dry out and condense, or are excessively stirred and separated, or individual materials are not melted, etc.
8) The eye of the needle is inserted: take off the cloth and move it to the edge, so that the cloth clipping needle penetrates into the edge of the cloth. In serious cases, it may cause rotten edges. If you find out, take measures in time. </p
