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2 Card TC 11
4 Innovations
16 Carding
38 Control, operation
42 Maintenance
48 IDF 2
52 Technical data
4 Card TC 11
Trützschler efficiency =
circumference x width of card cylinder
6 Card TC 11
80
60
40
20
0
0.7 1.0
1.5 2.0
MAGNOTOP –
THIS IS HOW SIMPLE OPTIMAL FLAT TOPS CAN BE
SECURE ECONOMIC UNNECESSARY FEATURES HIGHER ACCURACY WITH
ADVANTAGES DURING EACH TRANSLATE INTO SAVINGS OUT INITIAL GRINDING
CLOTHING CHANGE
The improved efficiency achieved With MAGNOTOP, the clothing
Maintaining consistent high quality re- by the easy replacement of the strips fit perfect from the start.
quires regular change of flat tops. For clothing strips without flats work- This is due to the reduced toler
this purpose, Trützschler has developed shop results in an immediate reduc- ances; the clothing strips are
the patented MAGNOTOP system tion of operating costs. Use of the attached to the flat bar via super-
together with Trützschler Card Cloth- MAGNOTOP system also eliminates strong neodymium magnets. The
ing. Its clothing strips, which are easy the otherwise unavoidable extra usual levelling that compensates
and quick to replace, offer unbeatable costs: deformations caused by assembly
economic advantages: Depending on can be eliminated. This prolongs
labour costs, savings of 300 – 1100 US$ No spare flat sets required the service life by one grinding
per card re-clothing can be realised. No service costs for re-clothing cycle.
Investments in a flats workshop (usu- No transport costs
ally 170 – 210,000 US$) are completely
eliminated.
Card TC 11 13
Higher efficiency
DUE TO FEWER PROCESS STEPS
FEWER STEPS ALSO SHORT SPINNING
TO REACH THE GOAL PROCESS
The "best" process steps are those Card TC 11 in the rotor spinning There is no shorter spinning process
that do not exist in the first place. mill. Efficiency is increased by a than feeding the card sliver directly to
Thus, problems can be avoided, multiple. Because the Trützschler the OE rotor spinning machine. This
errors ruled out and money saved. A card/draw frame couplings combine requirement is also perfectly met by
reduction of draw frames is of par- all the advantages of the Card TC the Integrated Draw Frame IDF 2.
ticular interest in the spinning mill. 11 with a proven and reliable draw
And this is precisely what the Inte- frame technology, the quality is
grated Draw Frame IDF 2 achieves improved as well.
by direct coupling to the Trützschler
Card TC 11 15
Fully-integrated tuft feeder DIRECTFEED • High production with even card feeding
Flexible Integral Feed Tray SENSOFEED+ • Short-wave levelling for a low sliver count variation
Precision Knife Setting System PMS • Adjustment of waste amount in no time at all
Aluminium flat bars without screw connection • Quick flat exchange, without tools
Magnet Flat System MAGNOTOP • Replacement of flat tops directly on the machine without tools
Precision Flat Setting System PFS • Reproducible flat setting in only a few seconds
Flat Measuring System FLATCONTROL • Objective and very precise flat adjustment
Infinitely variable setting of the flat speed • Exact adaptation to the fibre quality in only a few seconds
Computer control with touch screen • Simple operation and targeted maintenance
Thick place monitoring • Stops the card in case of excessive thick places in the sliver
WEBFEED with one roll • For the carding of man-made fibres or ELS cotton
Long- and short-wave levelling system • For perfect card sliver evenness
Special toothed belts for flat guiding • Flat replacement without tools
Highlights at a glance
Flexible Integral Feed Tray SENSOFEED+ for Fully-integrated Tuft Feeder DIRECTFEED with Setting Optimiser T-Con
perfect clamping and very precise short-term built-in air volume separator and segmented feed
levelling tray
Precision Flat Setting System PFS The measuring bar is a precision instrument Magnet Flat System MAGNOTOP
„Made by Trützschler“
Nep Sensor NEPCONTROL TC-NCT Precision Knife Setting System PMS MULTI WEBCLEAN – flexible for all applications
Card TC 11 18
Carding Control / operation Maintenance
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 21
SENSOFEED+
1 The flexible Integral Feed Tray SENSOFEED+
ensures controlled web feeding to the WEBFEED
Unit. Its feed table compacts the tuft web and
guides it to a knife-shaped feed tray tip. The
material at this top allows a partial elastic defor-
2
mation that occurs when material slubs are fed.
This deformation is only a few hundredth of a
millimetre and has hardly any influence on the
overall deflection of the feed tray. As additional
function, the Integral Feed Plate SENSOFEED+
can also include feed monitoring for the card.
3
4
7 8
WEBFEED:
The plus for gentle but efficient opening
The WEBFEED system consists of one large Fibre pre-opening is of decisive importance for
or three opening rolls connected in series. The the carding process. Therefore it makes sense
tufts are opened in a gentler way and to a higher here to precisely adapt to the respective applica-
degree than is the case with conventional licker- tion. In the process, the different versions are
ins. This results in an even and fine web that flexible and easy to replace:
increases the carding efficiency at the actual
main working points (between cylinder and flats/
carding segments) during the transfer to the
main cylinder.
• 3 rolls – first roll: Metallic wires e.g. cotton/man-made fibre blend yarns
Gradual opening
for maximum fibre
Tuft
size protection
ed
l spe (3-roll WEBFEED)
hera
Perip
ss
nene
ing fi
Cloth
g angle
Clothin
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 23
PMS:
Adjustment in no time at all
The main cleaning zone of the TC 11 lies in the Through the circular
area of the first roll of the WEBFEED system. adjustment the top edge of
the knife always remains at
Here, an optimal waste composition requires an an optimum distance to the
accurate mote knife setting. This is exactly what needles.
the successful Precision Knife Setting System
1 Feed roll
PMS provides. 2 The adjusting slide moves with
the knife on a circular path
The knife, which circles around the centre of the
around the centre of the needle
needle roll, is infinitely adjustable within sec- roll
3 With this lever the position of
onds. Thus, the distance of the knife point to the the knife is adjusted in no time
1
needles is exactly the same in every position. 4 The permanent suction keeps
the card clean in this area as
well
2
With this system, a small servo motor is the key This small servomotor
to increased user-friendliness and precision: The adjusts the knife circularly
around the centre of the first
knife can be circularly adjusted around the cen- roll of the WEBFEED.
tre of the first WEBFEED roll via touch screen –
and that even while the machine is running.
All values can be stored according to lot. For
extremely short transitions from one material to
the next, the setting values of the PFS and of
the PMS system, as well as the speeds of the
cylinder roll and WEBFEED roll, can be stored
according to lot in the memory of the control.
24 Card TC 11 Carding Control / operation Maintenance
1.28 m
The new width of the Trützschler cards of 1.28 m design was developed. This also includes new
is the result of an intensive development proc- statics and the application of new materials. The
ess. Initial analyses concerning an optimal cylin- level of precision used during manufacturing
der width revealed the following: A larger width contributes to the growth in productivity. During
would make the construction so massive that countless tests the technical concept was tried
it would no longer be economically feasible. A out, refined and, last but not least, tested as
smaller width wastes productivity. Based on this prototype in customer facilities. The results fully
concept, production parameters of the prede- met our expectations.
cessor model TC 7 were evaluated with the help
of T-Con sensors (see page 38), and the new
1.1
Flat
”active carding area“ [m2]
3.0
3.0 Post-carding
0.6
2,4
2.1 1.5
0.5 1.8
0.5
2.0 0.5
1.3
1.1
1.0 1.1
0.6 0.6
0.5
0
other card manufacturers TC 11
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 25
Pre-carding
Flat
Post-carding
The Trützschler Card TC 11 features the longest This job is assigned to the pre-carding area
carding section on the market. Carding quality with its cleaning and carding elements.
is ensured by optimal distribution over the three The higher the pre-opening, the more intense
carding areas. the carding, which in turn results in increased
In this regard, the cylinder area is of particular production. The large post-carding area takes
importance. The main focus is on the revolving care of the rest, thus ensuring even cleaner
flat: With an optimal number of flat bars, it is re- sliver and higher fibre parallelism.
sponsible for cleaning as well as extracting neps
and short fibres. To ensure its optimal function,
the fibre web must be prepared accordingly.
Of importance is
the proper balance
Carding section between pre- and
post-carding zone and
3.5
Pre-carding the flat
3.0 2.8
Flat
Carding section [m]
0.8
2.4 Post-carding
2.1
0.5 2.0
2.0 0.5
0.4 1.2
1.3
1.1 1.2
1.0
0.8
0.6
0.5
0.4
0
other card manufacturers TC 11
26 Card TC 11 Carding Control / operation Maintenance
14 h 2h
necessary once – which reduc-
es the approximately 14 hours
spent by personnel to less
than 2 hours.
MAGNOTOP-change of flat tops
The MAGNOTOP system was developed in cooperation between clothing specialists from
Trützschler Card Clothing and Trützschler card developers.
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 27
3
4
5
3
2
1 1
1 Aluminium flat bar
2 Clothing strips
3 Adhesive and
compensation layer
4 Neodymium magnet
5 Thin metal strip
2
300
240
Time [min]
180
120
60
0
Conventional high- TC 11
production card
Via remote control it is Replacement of flat bars requires one person to work only
possible to move the flat for approx. one hour.
service-purposes also while
card is at a standstill.
Each individual MAGNOTOP flat bar is made a special plastic strip. This arrangement has the
of high-strength aluminium profiles, which are advantage that a complete flat replacement can
lightweight and extremely stable. The flat bars be performed by just one person without tools
are directly connected via a cam to two toothed in less than one hour.
belts that ensure perfect guidance. The hard
metal pins at the ends of the flat bar glide across
3
4
1 2 3 6
This system performs the motorised adjustment A servo motor performs the
of the flat setting system in a precise, repro- flat setting on both sides of
the card.
ducible manner within seconds. From a central
control it ensures that the distance of all flat
bars in working position to the cylinder increases
or decreases. All that is required to select the
respective adjustment on the display of the
machine control. The adjustment is indicated ac-
cordingly and, same as all other settings, can be
managed in the lot memory.
30 Card TC 11 Carding Control / operation Maintenance
MULTI WEBCLEAN:
The tailor-made solution for each application
Cleaning element
This element consists of
a mote knife with a hood
under permanent suction.
It is designed to separate
tiny dirt particles, seed coat
fragments, dust particles,
and fibre fragments.
Carding element
The carding element
consists of two clothing
strips in a support
(TWIN TOP), which
can be equipped with
a number of different
clothing types and
finenesses, depending
on application area and
raw material.
Depending on application,
the MULTI WEBCLEAN
consists of the cleaning,
carding and cover
elements.
21,000
The suction ducts are 18,200
fastened entirely without 14,000
tools. They are pulled
off and put on with the
7,000
SNAPLOCK Quick-Change
System.
0
Other cards
TC 11
In comparison:
Other cards: 5500 m3/h at -1250 Pa
TC 11: 4200 m3/h at -740 Pa
-1200
-1200
4200
-600 -600
0 0 0 0
Other cards TC 11
Low exhaust air volumes and operating subpressures reduce the operating costs considerably.
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 33
TC-C:
A can changer as it should be
The can changer TC-C stands freely in front of the card, without mechanical connection. A service aisle between can
changer and card reduces the distances.
With TC 11, every metre of card sliver is checked is clearly superior to random laboratory checks
prior to its deposit in the can. This is made pos- because it is performed permanently and online.
sible by extensive, integrated quality monitoring Thick places are also reliably detected.
during which the sensor data for all relevant
areas are gathered: Upon request, the quality management can also
be supported by additional systems and tools:
• Sliver count
• Sliver evenness he online Nep Sensor NEPCONTROL TC-NCT
T
• Spectrogram permanently records the number of neps, dirt parti-
• Frequency of thick places cles and seed coat fragments (option)
The evenness of fed material, card sliver and Pictures or diagrams provide visual information,
draft deviation is clearly displayed on the same which often is superior to text messages (e.g. in
timeline. case of fault messages)
With the virtual roll bars below the continuously The error source calculated by the automatic
calculated spectrograms, the error sources can spectrogram analysis is shown directly in the
be located more quickly. gearing diagram.
Maintenance and clothing management benefit Production parameters can simply and quickly
from concrete additional information. be entered via touch screen.
36 Card TC 11 Carding Control / operation Maintenance
fragments.
With NEPCONTROL TC-NCT it is also possible
to establish a distribution profile of the nep and
particle level over the working width. Possible
clothing damage becomes immediately visible
this way.
The screen shows the current condition of the flat settings. To perform the setting, the
technician just needs to take one look at the screen.
38 Card TC 11 Carding Control / operation Maintenance
• T-Con distance optimisation Optimal yarn quality due to correct setting parameters
T-Con
PMS
Setting
PFS Sliver count Production Material Delivery speed
Setting
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 39
The T-Con Spacers can easily be replaced in just a few This sensor monitors the
simple steps and thus enable a reproducible setting of the cylinder temperature.
carding segments.
40 Card TC 11 Carding Control / operation Maintenance
TC-VSD:
Infinitely variable setting, without compromises
With this method, infinitely variable setting of
the required cylinder speed, and thus the WEB-
FEED speeds, is achieved via a frequency con-
verter at the cylinder's drive motor. The control
is carried out directly on the screen of the card,
which significantly simplifies frequent material
changes. Furthermore, the infinitely variable
rotary speed setting TC-VSD can be used to
compensate the wear of the cylinder clothing by
a slightly higher cylinder speed, thus maintaining
a stable nep level.
Variation coefficient
length spectrum.
1. Card feeding
2.00
In Trützschler installations, already the material
flow to the card is continuously controlled via 1.50
Integrated tuft
feeder levelling
247,919
252,000
201,600
151,200
50,400
0
Other cards
TC 11
other
cards: Installed power 42 kVA = 24 kW
consumed power approx. 17 kWh
Completely maintenance-free: The digitally controlled TC 11: Installed power 36 kVA = 21 kW
consumed power approx. 15 kWh
servo drive has neither carbon, brushes nor fans, and is
completely enclosed.
TC 11-S:
The best man-made fibre card ever
3
9
5
7
7
6
10
The differences between
man-made fibres card and
cotton card are significant.
11
8
12
46 Card TC 11 Carding Control / operation Maintenance
Modified WEBFEED:
Higher efficiency, quality and service life
50,000
Service costs /10 years [US$]
40,000
30,000
10,000
0
Clothing Needle
• The fibre-guiding elements in the tuft feeder are made of stainless steel
The Integrated
Draw Frame IDF 2
with automatic
can changer
The production-related and economic advan- The strength of the IDF 2 system is also appar-
tages that can be achieved with the Integrated ent in its design. Thanks to the space-saving
Draw Frame IDF 2 are enormous: arrangement of the draw frame unit above the
• requires less space, can changer, it requires no more space than a
• requires less cans, regular can changer.
• simplifies can transport,
• lowers power consumption and The IDF 2 allows processing of all fibers com-
• reduces personnel and operating costs. mon in rotor spinning. For coarse and medium-
fine high-quality OE yarns up to Ne 24 we rec-
Due to increased sliver adhesion and adapted ommend the combination of TC 11 and IDF 2.
fiber orientation, the slivers have a better run- This solution offers improved yarn quality and
ning behaviour in downstream processing than increased economic efficiency.
draw frame slivers.
Rotor spinning
3.2
has a positive savings of more than 84,000 US$.
impact on the
fabric appearance,
2.8 particularly
on knitted fabrics
2.4
2.0
È Energy costs US$/year
360,000
323,936
1.6
1.2 240,000
239,187
0.8
0.4
0.0
TC 11 + IDF 2 TC 11 + TD 7 TC 11 + TD 7 + TD 8 120,000
13.8 0
13.6
CV %
13.0
12.8
40
30
14.4
14.0
cN/tex
13.6
13.2
12.8
12.4
12.0
TC 11 + IDF 2 TC 11 + TD 7 TC 11 + TD 7 + TD 8
Yarn strength
50 Card TC 11 Carding Control / operation Maintenance
The combination of the Trützschler Card TC 11 Advantages of direct card and draw frame
with the Integrated Draw Frame IDF 2 presents combination:
an economically attractive and technologically • Less material buffer in the process,
practical solution. Instead of a conventional can therefore less tied-up capital
changer, the Integrated Draw Frame IDF 2 is • Shorter throughput times
connected directly to the card, thus eliminating • Reduced operating work
a draw frame passage. This configuration is also • Reduced building area
very space saving, since the otherwise required
space for a complete draw frame with can
magazine for the card cans is eliminated.
540 m2 280 m2
Levelling quality without compromises ensures reliable levelling of the draft. A second
Immediately before being fed into the drafting sensor is positioned immediately behind the
system, the card sliver is scanned by the reliable drafting system. Here the sliver is permanently
Trützschler sliver sensor; then it is levelled via checked to ensure that every metre deposited in
the drafting system. The close physical prox- the can corresponds to the required quality.
imity of measuring point and drafting system
Sensor to determine sliver fineness and quality sensor Simple and clear operation via the card display
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 51
Drafting system and motor are quickly and easily accessible Closed casing
52 Card TC 11 Carding Control / operation Maintenance
600
3410
2150
3576 mm
3576 mm
3576 mm
L6
L3
L3
500 mm
L1
50
L4
0m
m
L1
L5
L2 L2
16
14
12
10
8
6
4
2
0
0 20 40 60 80 100 120 140 160 180 200 220 240 260
Production [kg/h]
54 Card TC 11 Carding Control / operation Maintenance
Equipment, standard
Spectrogram analysis
Options
Options and additional equipment for the individual, tailor-made Trützschler Card TC 11:
Application-oriented optimisation:
The drafting system is positioned on the can The can delivery is made onto a can delivery ramp.
changer. For this reason, the Integrated Draw Alternatively, it is also possible to transfer four full
Frame IDF 2 requires no additional space. cans each to a can carriage.
2110 mm
450 mm
2750 mm
1000 mm
Man-Made Fibre Card TC 11-S Integrated Draw Frame IDF 2 Technical data Card TC 11 57
Equipment characteristics
Draft: 2-fold
Drafting system: 2 over 2 with pneumatic loading of top rolls and integrated
suction
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mistakes or technical changes. Photographs and illustrations are of informative value only and some show special optional equipment
that is not included in standard delivery.
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claims against us or the respective author pertaining to material or immaterial damages caused by the use or circulation of the
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