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Card TC 03

Index

Page

1 Card TC 03

3 innovations
8 design
10 Concept
12 Accessibility
14 Tuft feeder DIRECTFEED Integrating bowl
15 SENSOFEED Pre-opening system WEBFEED
16 Precision knife adjustment system PMS
18 Drum area
19
20 MULTI WEBCLEAN System
22 flat system
23 PFS Precision Flat Adjustment System
24 Veil delivery
25 can changer
26 suction system
27 drives
28 regulation systems
29 Quality control
30 computer command
32 Value Added Packages TC-FS Yarn
33 Title Package TC-MS Synthetic
34 Fiber Package TC-HS High
35 Production Package TC-ES
36 Economy Package
37 TC-OS optimization package Nep sensor
38 NEPCONTROL TC-NCT Flat measuring system
40 FLATCONTROL TC-FCT Fiber length measuring
42 device LENGTHCONTROL TC-LCT

44 Waste sensor WASTECONTROL TC-WCT

45 System TC 03
46 Material feeding
48 Configuration / options
50 Technical data

53 IDF integrated draw frame

71 Draw frame TD 03

Tape Technology Trützschler

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Trützschler Tape Technology

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 Card TC 03

More of Productivity and quality at the highest level Mainly, the optimization of the pre-opening and
10,000 cards, Experience with more than 10,000 cards from the DK carding area significantly improves the quality. The

worldwide 803 and DK 903 series, with the 3-cylinder pre- TC 03 Trützschler card is highly flexible and, where
opening unit WEBFEED, forms the basis for the necessary, allows you to configure a tailored system
development of the new TC 03 card from Trützschler. for each application case through optimized
configurations and options.

Only the TC 03 Trützschler card offers:

Fully integrated tuft feeder DIRECTFEED - High production in uniform card feeding
SENSOFEED integrating bowl - Short period adjustment for constant flow
of dough

WEBSPEED tape former - completely maintenance free

PMS precision knife adjustment system - Adjusting the volume of waste in a single operation

Waste sensor WASTECONTROL - Automatic optimization of waste volume

Aluminum flat rods without screw connection - Quick change of flats without tools
PFS precision flat adjustment system. PFS - Reproducible flats adjustment in seconds

FLATCONTROL flat measuring system - Objective and precise adjustment of the flats

Linear adjustment of the speed of the flats - Exact adaptation to the raw material in seconds

Electronic drum brake - Reduces cleaning and maintenance times

Added value packages - Tailor-made adaptation to each application

NEPCONTROL nep sensor - Online measurement of neps and trash particles

Computer control with touch screen - Simple operation and targeted maintenance

digital engine control - Maintenance-free and high-precision

Spectrogram control - Turn off the card if there are errors in the spectrogram

Coarse stitch supervision - Prevents very high amount of points

thick in the tape

Length sensor LENGTHCONTROL - Ultra-fast short fiber measurement

Without a doubt, the TC 03 card also uses – Long and short period regulation system.
components that have been proven time and time – Special toothed belt for flat guide.
again in the DK 803 / DK 903 card models: – Long life gasket with high quality steel for pre-
– 3-cylinder WEBFEED pre-opening unit for a pre- opening, drum and delivery.
opening process without harming the fibers. – High-precision aluminum elements with highly
polished surfaces in the fiber conductive areas.
– Needle cylinder in 1st position, less aggression to
the fibers and with a useful life 10 times longer in – Central security lock.
relation to gaskets.
– Supervision of thick and metal points at the
entrance.

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 design

The function defines the

form

Trützschler Tape Technology

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High-tech aesthetically packaged The new
development of the TC 03 is documented through
the re-presentation of the current Trützschler
design. For Trützschler, design not only means
good looks, but first and foremost functionality.

The simple operation of the machine, the good

accessibility for maintenance and the reduced
operating costs, provided by the low consumption
of electrical energy and low air intake, were the
strategic objectives of development and greatly
influenced the design.

Tape Technology Trützschler

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 innovations

Fully integrated DIRECTFEED tuft feeder with

installed air separator and segmented feed bowl

SENSOFEED integrator tray for perfect fixation

and precise adjustment in short periods

PFS precision flat adjustment system

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PMS precision knife adjustment system Duplicated area of pre- and post-carding zones Computer control with touch screen
for flexible and application-appropriate
equipment, with cleaning and carding elements
Flat measuring system FLATCONTROL TC-FCT NEPCONTROL TC-NCT nep sensor Waste sensor WASTECONTROL TC-WCT
Optionally new can changer with … or integrated IDF dowel for round or
independent drive … rectangular cans

- PMS precision knife adjustment system - DIRECTFEED tuft feeder, fully integrated with
installed air separator and segmented feed
- Supervision of thick and metal stitches
bowl
- PFS precision flat adjustment system
- SENSOFEED integrator tray for perfect web
- LENGTHCONTROL fiber length measurement fixation and precise adjustment in short
system periods

- Computer control with touch screen - WEBFEED 3-cylinder pre-opener system

- Added value packages - Doubled area of pre- and post-carding

zones for flexible and application-
- FLATCONTROL flat measuring system
appropriate equipment with cleaning and
- NEPCONTROL nep sensor carding elements

- Linear adjustment of the speed of the flats - aluminum flat rods

- Waste sensor WASTECONTROL - New optional can changer with independent

drive or integrated IDF draw frame for round
- Electronic drum brake
or rectangular cans
- digital engine control
- WEBSPEED tape former
- Integrated quality control

- Long and short time adjustment

- Central security lock

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 Concept

a construction
brand new 2.17 m 2.82 m

DK 903 TC 03

The length of the carding zone is decisive for quality

pre-carding

flats

post carding

Longer carding line. The TC 03 card features a completely new

Carding quality is initially decided in the drum construction to provide more space for these
area. The circulating flat, with an optimized important areas. The type of path that each
number of flat rods, is essential for cleaning fiber takes on the card is decisive. The longer
and separating neps and short fibers. This is the carding area, consisting of the pre-carding
particularly true for all natural fibers, but area, flats and post-carding area, the greater
conditionally also for synthetic fibers. the quality potential of the machine.

In order for circulating flats to work optimally, The quality potential of the TC 03 can be
they need a well-prepared fiber web. This is used flexibly
provided by pre-carding area,with its cleaning The technological improvements of the TC 03
and carding elements. It is valid to say that the card can be used, initially and in a practical
greater the pre-opening, the more intensive the sense, to increase production. On the other
carding and the greater the production. hand, this potential can also be visibly converted
into quality gains. The practical result will, in
Onepost carding areaThe enlarged tape most cases, be a combination of the two: an
provides a cleaner ribbon and greater fiber improvement in quality and an increase in
parallelism. productivity.

920 mm + 48% Post-

carding
620 mm

1000 mm
flats
1000 mm
fiber path

900 mm + 63% Pre-

550 mm
carding

DK 903 TC 03

Comparison of carding areas between DK 903 and TC 03

Trützschler Tape Technology

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Process optimization, focus of our
development
Through optimized process flows, profitability
and quality are more consistently improved. For
this reason, the concept of process optimization
TC 03
has a high value for Trützschler and, for the new

carding quality
TC 03 card, concrete meanings:

DK 903
High profitability:
- High productivity;
- Low operating costs;
– low consumption of electricity; high cards
production
– low consumption of compressed air;
conventional
– reduced filtering operating costs;
– reduced maintenance.
Production

High quality:
The TC 03 card combines high productivity with high
- Online and permanent supervision of the most quality card sliver
important parameters:
– neps,
– residual trash, High precision construction elements and
– tape uniformity, precise adjustments.
- thick stitches, For carding quality, compliance with the
– spectrogram. selected settings is decisive.
- Objective and reproducible adjustments; For example, setting the distance from the flats to the drum
- Application optimized configuration must be maintained across the entire width and working
area of the flats.
To achieve this, two prerequisites must be
met:
1. All constructive elements of the set must be
manufactured with absolute precision and be
within the limits of tolerance.
2. Adjustment devices and auxiliary means must
allow accurate and reproducible adjustments. It
was these prerequisites that guided the
development of the TC 03 card.

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 Accessibility

The design meets Perfect accessibility reduces the time for Access to this side is secured by a central
the function cleaning, maintenance and dressing treatment security lock. This makes the covers of the
Design meets function. This is not just a slogan for drives unnecessary, which only make
Trützschler: the top cover of the card is suspended maintenance more difficult.
by two steel rods, without supports. With this The left side is accessible at any time for visual
design solution, there are no more vertical supports controls, even during production. Additionally,
or door frames, which always make access difficult, many small items have been optimised:
to a greater or lesser degree. The doors can be cleaning gates, eg in the lower tuft feed silo,
dismantled, without tools, in a few minutes. reduce cleaning time; or the NEPCONTROL nep
sensor can be mounted and removed even
All drives are concentrated on the right side of more easily using the telescopic guide.
the machine.

The doors can be completely removed and all areas of the card are freely accessible.

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Modular construction The can changer has no mechanical connection
With the modular construction of the TC 03 card, to the card. This not only simplifies operation,
maintenance has also been simplified. For example, but also improves accessibility for cleaning
the WEBFEED pre-opening unit can be exchanged work.
as a single piece, without dismantling the
SENSOFEED integrator bowl. Both the flat cleaning
installation as well as the complete web delivery
can be dismantled in a short time.

with the tools

specials that come with
delivery, replacing the
WEBFEED pre-opening unit
is a matter of minutes

Machine maintenance points have been Quick and accurate adjustments

eliminated. Important adjustments, eg adjusting the knife in
Chains, with periodic lubrication, belong to the pre-opening or optimizing the spread of the flats,
past. Gearboxes, with periodic oil changes, are can be carried out during production through small
no longer needed. manual adjustments.
Direct current motors, with constant change of
carbon or brushes, no longer exist. Digital servo
motors or frequency controlled motors have
eliminated these maintenance points. An
additional advantage is the lower consumption
of electrical energy, as each gearbox has greater
or lesser efficiency and has an unnecessary cost
of drive energy.

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 DIRECTFEED tuft feeder

For DIRECTFEED – the tuft feeder for the

uniformity still TC 03 card
biggest of the tape
The DIRECTFEED tuft feeder is a component
integrated into the card. Integration into the card
means, the tuft feeder delivery roller is identical to
the card feed roller. The current handing over of
the veil is suppressed. Faulty stretches due to
wrong or non-optimized adjustment no longer
occur.
The tuft feeder works on the Trützschler double
silo principle. Improved air outlet elements in
the upper silo allow for more uniform feeding
and greater possibilities for adapting the
flexible configuration of the cards to the
feeding lines.
In the lower silo, the basis for excellent CV values
Self-cleaning stainless steel comb
of the ribbon is formed through an optimized
geometry and a longer material flow. The air
outlet combs, directly and permanently sucked Better sliver uniformity, even at
in, are located before the card feed cylinder. The the highest productions
web is formed only here, a few centimeters A large stock of material in the upper silo of the
before the point of entry into the feed roller. tuft feeder, 1200 mm wide, guarantees stable
and uninterrupted operation. Tape uniformity is
directly influenced. The inlet bowl is subdivided
into 5 spring-tensioned unit segments. This
bowl holds the veil more effectively and without
harming the fibers.
1 The high-speed opening cylinder, equipped with
relatively few needles, opens the flakes without
harming the fibers and prevents the formation of
neps.
two

3
4

DIRECTFEED tuft feeder

1 High volume top silo

twoIntegrated air separator
3 Feeding cylinder, electrically
coupled with the card
feeding cylinder
4 Segmented well for secure fixation
5 Opening cylinder provided with non-
aggressive needles to the material
6 Closed air circuit with integrated fan

7 Self-cleaning air outlet combs

Trützschler Tape Technology

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 SENSOFEED integrating bowl

The perfect feeding system for the card. The to the point of delivery on the needle cylinder of the Food
SENSOFEED integrator tank of the TC 03 card WEBFEED pre-opening unit. Each of these spring exact through
works with a feeding cylinder, a feeding table elements adapts exactly to the momentary mass of of driving
and a measuring lever. The feeding table the veil to be transferred. This means that the spring
controlled
compacts the tuft web and guides it to the spring elements are subjected to different displacements in
of the veil
elements of the measuring lever. This lever is the variation of mass.
equipped with 10 downward-pointing moving The displacements of the 10 spring elements are
spring elements, each 100 mm wide. converted into a single signal and used as the
current value for the adjustment of short periods
Thanks to the careful formation of the tip, the (see page 28).
spring elements guide the web in a controlled way.

The TC 03 card entry system

two 3 4 5
1 A special feed roller gasket prevents fiber
tangling
twoSpring-tensioned feeding table Spring-
3 tensioned measuring lever Spring
4 elements
5 First cylinder of WEBFEED pre-opening unit

Extended protection against foreign and recognized and lead to the immediate stop of the
metallic parts card. An electrical reversing circuit makes it
The SENSOFEED integrator tank contains, as an possible to easily remove foreign parts before they
additional function, a card inlet control. Metallic damage the card.
parts or thick spots on the veil are

SENSOFEED integrating bowl

Tape Technology Trützschler

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 WEBFEED pre-opening unit

opening in stages Opening with the pre-opening unit without High degree of openness – the basis for high
to a maximum harming the WEBFEED fibers quality

fiber protection The WEBFEED system consists of three The opening in stages by three cylinders preserves
sequential opening and cleaning cylinders. The the fibers. At the critical point, between the feed
opening of the flakes is better than in roller and the pre-opener, the fibers need to be
conventional pre-openers, and without harming accelerated suddenly. The first WEBFEED roller
the fibers. Delivering a thin, uniform web to the rotates much slower than the conventional single
drum makes carding efficiency at the main work card pre-opener.
points (between drum and flats/carding This does not harm the sensitivity of the fibers.
segments) higher. The card can operate with In cotton processing, the first cylinder is
higher drum speeds, thinner clothings and provided with short needles. These needles pull
tighter settings. In addition, newly developed the flakes, without harming them, from the
drum clothings, which have as a prerequisite the pressure point of the spring elements of the
feeding of a thin and uniform web, can also be SENSOFEED integrator bowl. The second and
used. third trimmed rolls further open the flakes and
form a web.

peripheral speed

Trim Density

Trim teeth angle

Step opening for maximum

fiber protection

1 for processing
cotton, the first opening cylinder is
provided with needles that do not
harm the fibers
twoThrough a higher peripheral
5 velocity, the fibers pass without
damage to the next cylinder

3 The third cylinder delivers a

thin veil to the drum
4 Knife position can be
changed externally through
manual operation
5 The radius of the carding
segment is adapted to the
cylinder geometry
6 bearings exempt from
maintenance
7 Optional WASTECONTROL TC-
7 4 1 62 5 3 WCT waste sensor mounting
to minimize loss of good fibers

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Less maintenance and longer trim life Reduction of neps already in WEBFEED
Unique is the effect of nep reduction already
The needle cylinder has a lifespan of approx. before the drum. In this way, the WEBFEED pre-
10 times longer than conventional pre- opening unit reduces the machine's carding
openers with gaskets. The gaskets of the workload between drum and circulating flats.
second and third cylinders are made of special
steel. They have the same lifespan as a drum
gasket.

A special bonding technique prevents the needles from falling

out and the fibers from sticking to the needle base

Competitors: Trützschler:

For a long service life, the needles of the first opening The needle is not always The needle is always guided
cylinder are made of special steel. centered. Fibers can get exactly. Excess binder
caught between the needle adheres to the needle
and the edge of the hole

The WEBFEED pre-opening unit can be replaced as a complete unit in a short time

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 PMS precision knife
adjustment system

The adjustment takes New solution for quick knife adjustment The first PMS accuracy. The knife moves in a circular fashion
only seconds cylinder area of the WEBFEED system remains the around the center of the needle cylinder and can be
main cleaning zone on the card. The adjustment takes adjusted linearly.
into account the importance of optimized waste In this setting, the distance from the knife tip to
composition. The degree of cleanliness is influenced by the needles remains exactly the same in all
the distance from the knife to the needle tips and the positions. Adjustment takes only seconds.
distance from the knife to the pressure point between
the feed roller and the needle roller.

Until now, adaptation could only take place by

choosing knives of different lengths. The knives
had to be dismantled, reassembled and
readjusted.
This costly process was abolished in the TC 03
card. A quick adjustment system was
developed for this card: the

Knife adjustment is possible even with

the machine in motion
The card does not need to be turned off as the
adjustment lever is freely accessible as it is mounted
on the left side of the machine. Adjustment is possible
even during production. An inspection of the
transparent suction channels immediately shows the
result of the new adjustment.

This lever allows you to adjust the knife with a simple

manual operation.

two

With circular adjustment, the knife tip always remains at an optimal distance from the needles

1 feeding cylinder
twoThe adjustment table moves with the knife in a circular path around the center of the needle cylinder This
3 lever allows the knife position to be adjusted through a simple manual operation

Trützschler Tape Technology

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 drum area

The drum – a precision component The drum any hand soldering. Special roller bearings, with The accuracy
is the central element of the card. It has a almost no backlash, are mounted on the drum in manufacturing
diameter of approx. 1.3 m and a working width shaft before grinding. These maintenance-free is decisive
of one meter. This results in a trim surface of bearings, common at Trützschler, do not
over 4 m two . require periodic lubrication. After the grinding
The precision in its manufacture is decisive for process, the drum surface is precisely hardened
the quality of the carding. For this reason, to ensure maximum eccentricity tolerance of
Trützschler produces these cylinders in-house thousandths of a millimeter.
using machines specially developed for this The drum carding surface is made up of 10,000
purpose. Pig iron is no longer used as it used to m of clothing wire, approx.
be, but special steel is used as raw material. 6 million points. Undoubtedly, the placement
Relative to pig iron, steel remains stable for a of the trim cannot impair the eccentricity
long time. A robot welds the covers to the sides, tolerance.
more accurate and reliable than

Image of drum manufacturing

Placing the trim is a delicate process that requires a lot of experience.

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 MULTI WEBCLEAN System

Increase of 60% more usable area in the pre- and By moving the WEBFEED pre-opening unit and
production and post-carding zone delivery unit below the drum, more space has

improvement of
Improvements in the WEBCLEAN system have already been created for the pre- and post-carding
brought numerous increases in production and functions.
quality
improvement in quality in the card models that
preceded the TC 03 card. Now another big step in
development has been taken.

pre-carding
50% active surface 70% active surface
flats

90° 90° post carding

50° 50°
80° 80°

DK 903 TC 03

The active surface of the drum trim has been increased

bespoke configuration 1. Cleaning element

In order to fine-tune the carding conditions to the This component is formed by a cleaning knife
specific application, that is, to the raw material, the with a permanent vacuum hood. It is responsible
production volume and the expected quality, a for separating small particles of trash, fragments
super flexible tool was created: the MULTI of seed husks and dust particles. In addition,
WEBCLEAN system. fiber fragments are separated.
In the pre- and post-carding areas of the drum, 10
special elements of the MULTI WEBCLEAN system
can be installed per drum in the most different 2. Carding element
combinations. The first and last elements are fixed. This element is composed of two strips of trims
The other eight positions can be occupied flexibly in a carrier (TWIN TOP). A series of different
and according to the tasks, with the following types of trims and densities are available,
elements: depending on the place of use and the raw
material.

control element carding element

cleaning element cover element

The four different elements of the set

Trützschler Tape Technology

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3. Control element 4. Covering element
This newly developed element is similar to the If none of the elements described above are
cleaning element, but it has a totally different mounted in the eight variable positions of the pre-
function. Through the directed action of the air flow and post-carding areas, a cover element is
on the surface of the drum, the function of the mounted.
carding and cleaning elements is optimized. For the This high-precision aluminum profile is
same high quality of the card sliver, there is less provided with a polished surface to avoid air
waste separation. turbulence and unnecessary fiber friction.

two two

3 3

1 1

MULTI WEBCLEAN configuration example for polyester processing

1 Fixed configuration cover profile

twoFixed configuration cleaning element
3 Flexible configuration for 8 elements

The exchange takes place in a few minutes In principle, each element can be mounted in
Changing elements is very fast. Once exactly each of the 16 positions. The card is supplied in a
adjusted, they can be disassembled and configuration that optimally meets most
assembled without the need for re-adjustment. applications. For special applications, eg
This is provided by specially developed synthetic fibers or fine worsted yarns, specially
fasteners. formed packages are available (see pages 32 to
37).

Tape Technology Trützschler

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 flat system

changing rods Safe in operation and low maintenance through special synthetic. The complete exchange of flats
of flats without the unrestricted use of high-tech components can be carried out by one person in less than an

tools in hour. As there is no longer any conventional

Flat rods are made of aluminum profiles, light lubrication with grease or oil, the entire flat area
one hour
and stable in shape. They are moved by two remains clean and maintenance free. With the use
toothed belts and connected to them through a of carbide sliding pins, grinding the ends of flats in
pin, without any other fastening element. the renovation of the clothing was also eliminated.

The carbide pins, fixed at the ends of the flats

rods, slide over a tape of material

4 1 5

two 3

The flat system Flat rods can be fitted to the timing belt pins without tools

1 Special timing belt with pins to fix flats rods

twoPrecision flexible arch with 6 adjustment

3 points Precision flats adjustment system PFS 2-
4 cylinder flat cleaning device
5 Tool-free replaceable aluminum flat rods

Linear adjustment of the speed of the flats to the Longer service intervals due to a new flat
material cleaning device
A linearly adjustable drive makes it possible to
adapt the speed of the flats to the material. The new flat cleaning device is even easier to
adjust. After technical service work, there is no
need for readjustment. The adjustment once
made can be reproduced quickly and safely. The
results are shorter service times, longer service
intervals and security against misadjustments.

Trützschler flat rods

1 Optimized, lightweight aluminum profile Securely 1

twoattached flat gasket Wear-free carbide slide pins
3 Synthetic clips
4 3
5 Cleaning felt keeps synthetic slip material clean

two
Trützschler Tape Technology

22
 PFS precision flat
adjustment system

A big step towards better carding The adjustment of

quality 300
the flats is decisive
Spinning operators are aware of how important for the result
240

time [min]
careful card adjustment is.
The decisive set point for quality is the distance 180
between the flats rods and the drum. If, for
120
example, the fit is too tight, this can lead to
high wear on the clothing and the resulting
60
high costs. If the adjustment is too far, high
neps values on the tape may occur. 0
The precision flat adjustment system makes it Conventional high TC 03
production card
possible to centrally adjust all the flats in
relation to the drum in a few seconds. The Adjusting the flat rods

distance, once adjusted exactly, allows Replacement of flat rods

subsequent adjustments to be made with the

To change the flat rods, it only takes one person an hour
PFS system during the entire life of the gasket
set. For standard regulation, it is recommended
to use the FLATCONTROL TC-FCT flat measuring
system (see page 40).

PFS precision flat

4 5 adjustment system

1 flexible metal bow

twoWear-free special
synthetic material guide
3 adjustment lever
4 High precision aluminum
flat rods
5 Timing belt with pins to
move the flats
6 The setting can be
read directly from a
scale
1 two 3 6

Adjustment with the lever The engine tuning variant

Precise, automatic and central adjustment of the tion to the default setting. In the case of motor
flats On each side of the card, a manual or motor- adjustment, the position is selected and indicated on
driven adjustment element is turned. This increases or the machine control display. What once required the
decreases the distance of all flats rods in working full attention of an experienced mechanic, on the TC
position from the drum. In manual tuning, a scale 03 this is done in seconds, precisely and reproducibly,
indicates the current setting in relation to the with the press of a key.

Tape Technology Trützschler

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 delivery of the veil

Stability Reduction of tape breaks through WEBSPEED

operational without tape former
tape break The web delivery to the TC 03 card was
developed from the point of view of fully
automatic and safe web guiding from delivery to
WEBSPEED. Self-adjusting, maintenance-free
side cylinder seals prevent dirt from entering
critical areas.

A tape former for almost all fibers. The proven

WEBSPEED tape former from Trützschler bundles
the web and feeds it into the measuring hopper. In
order to also be able to optically evaluate the web The press of a key allows visual control of the veil

quality or to take samples, the tape former can be

opened with the press of a key.

For processing extremely short fibres, the card

can be optionally supplied with a cross sliver
stripper.

Veil and tape formation, proven thousands of times

two 4 56 7 8
1 Delivery cylinder coated top and bottom
twoThe peeling cylinder is equipped with a special
gasket that prevents tangling.
3 The guide profile can be replaced by the NEPCONTROL
nep sensor
4 Compressor cylinders provide uniform web
transport
5 Veil support holds the veil especially at high speeds

6 The WEBSPEED tape former is absolutely

maintenance-free
3
7 The sliver quality control sensor is integrated into
this funnel.
8 Calender rolls compress the tape so that it can be
1
deposited correctly in the can and be removed from
the can without fail.

Integrated online neps control

In the web delivery area, the Trützschler
NEPCONTROL TC-NCT nep sensor can be mounted
under the stripping cylinder instead of the guide
profile. NEPCONTROL permanently counts the
amount of neps, trash particles and cones and
informs them to the machine's command. It
evaluates the data and displays it on the screen.
Transmission to Barco's Tape Information
System KIT is also planned.

Mounting the neps sensor just got even simpler with the
new telescopic guide

Trützschler Tape Technology

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 can changer

Standard delivery with automatic can can changer

changer pattern
The standard supply of the TC 03 Trützschler card
comprises a fully automatic can changer for cans
up to 1500 mm in height and 1000 mm in
diameter. On request, it is also possible to supply
a magazine for manually changing cans.

New building
The can changer has been completely
redesigned. It is quite identical to the
Trützschler draw frame can changer TD 03.
Technologically important components such as
sump plate or extractor cylinders can be used
on both machines, reducing spare parts
inventory.

The new can changer, with independent drive, is freely arranged

in front of the card and without mechanical connection

Better accessibility and simpler operation The o trocador. Estiragem erradas e rupturas da fita,
new can changer is freely arranged in front of the causadas por uma alta estiragem, foram eliminadas.
card. It is accessible from all sides. A service aisle A fita é rompida automaticamente na troca de latas.
between the can changer and the card provides
shorter paths between the cards. The independent
drive allows a very sensitive adjustment of the
stretch between the card and

A livre disposição economiza espaço e reduz os tempos de atendimento

1 É possível uma distância de somente 3 m de centro a centro O

2 corredor de serviço encurta a distância entre as carda

Tecnologia da Fita Trützschler

25
 Sistema de aspiração

Aspiração Alta rentabilidade externa. A rentabilidade otimizada é proporcionada

permanente O desenvolvimento do novo sistema de aspiração para pela baixa subpressão de contato (somente 760 Pa) e
a carda TC 03 teve como meta a melhoria da pelo baixo volume de ar (somente 3900 m3/H). These
rentabilidade. A aspiração permanente de todos os values did not increase in relation to the DK 903
pontos tornou-se padrão. Se necessário, também é precursor card, despite the TC 03 having more suction
possível a configuração com uma caixa de filtragem points.

The suction channels have been concentrated on one side of the machine

Unvarying carding quality through perfect simple handling

suction The freely exposed suction channels are made of
On the TC 03 card, all cleaning and dust ABS, a break-resistant synthetic material. Other
extraction elements are vacuumed directly and aluminum channels are integrated into the
continuously, preventing dust and residue machine's moving components. This resulted in a
depositing. This feature turned out to be an rigid and robust construction that provides space
advantage especially in the processing of sticky, savings. The channels can be dismantled without
caramelized cotton. tools by simply pulling them out. On assembly,
the tubes are easily fitted in a matter of seconds.

The new generation of suction channels features optimized The suction channels are fixed completely without
cross sections to reduce ingress of dirt and friction tools. They are joined and disassembled through
fittings.

Trützschler Tape Technology

26
 drives

The drive concept ensures high card Saving

sliver uniformity electricity
Different motors and transmission elements form and exempt from
the drive solution for the TC 03 card. Special three-
maintenance
phase motors drive the drum and pre-opener
separately. On request, the rotation of these motors
can be regulated. Special, maintenance-free belts
guarantee a long service life. The web delivery on
the TC 03 card is equipped with an adjustable,
independent drive. Thus, it is possible to select the
ideal stretching for each speed. Even during
acceleration and braking, the control adjusts the
right stretch for the current speed. This means
more uniform tapes on the cans, from the first
meter to the last meter.

Digital controls for newly developed servomotors are

reliable and economical
Digital drives for the first time on
cards Trützschler technical service also for
The all-new, maintenance-free digital drives are engine controls
used for the first time on cards, feed rolls, The digital controls for the servomotors were
delivery machines, web delivery and can developed and manufactured by Trützschler,
changer. These drives reduce electrical power which guarantees high reliability even in extreme
loss through high efficiency. Additionally, the temperature and humidity conditions in the
eccentricity is better at low rpm and the rotation spinning mills. This constellation guarantees long-
accuracy is higher. This results in more accurate term technical assistance and the supply of
tuning and better tape CV values. Maintenance- replacement components.
intensive gear units, eg in the delivery cylinder
drive, are no longer available on the TC 03. The Low electrical energy consumption through
newly developed drives are brushless and individual drives
therefore absolutely maintenance-free. The The individual drive system minimizes electrical
secondary drives, such as the tuft feed cylinder energy consumption. This fact contributes to the
or the flat drive of the TC 03, are also brushless removal of gearboxes that, on the one hand,
drives with linear adjustment. consumed energy unnecessarily and, on the other
hand, individual drives allow the exact
configuration of the motors for each application
case, increasing their efficiency.

25
r 100
0 kg]

20

15

10
von H. Hösel
5

0
0 30 60 90 120 150
Production [kg/h]
Drum rotation (min -1)
400 500 600

The TC 03 has a low specific consumption of electrical energy

Servomotors are encapsulated and do not require regular

cleaning and maintenance
Tape Technology Trützschler

27
 regulation systems

systems of Exact tape title maintenance, not by 4. Adjustment of short periods

regulation, chance The TC 03 card is equipped with a short period

synchronization The production of a uniform card sliver is the result adjustment of the sliver title.
of a series of synchronized measurements. This system greatly improves the uniformity of the
perfect

1. Flow of material to the card

The material flow on the card is continuously 3.00

regulated in Trützschler installations (CONTIFEED 2.50

system). Production requests from all cards in a

Coefficient of variation [CV %]

2.00
line determine the momentary production of the
last machine on the cleaning line. This continuous 1.50
card feeding forms the basis for a uniform sliver. 1.00

0.50

2. Feeding the cards 0

The principle of two tuft feeding silos, with 1 two 5 10 20 50 100

continuous flow of material with regulated pressure Cut length [m]

in the lower and upper silos, offers greater without regulation Trützschler TC 03

uniformity. For example, when starting and

TC 03 guarantees excellent uniformity values across the
stopping the card, adapting the rotation of the tuft length spectrum
feed cylinder prevents errors in the momentary
production of the card. card sliver and becomes active below 1 m of
sliver length. The thickness of the tuft web is
3. Adjustment of long periods constantly explored in the SENSOFEED
The sensor on the card's sliver hopper measures integration vessel.
the sliver thickness. The feed cylinder rotation is From the values obtained, the card control
regulated in a similar way to this signal. A single calculates a possible change in the rotation of
sensor covers the entire spectrum of normal card the feed rollers. This short period change is
sliver titles. superimposed on the signal coming from the
long period setting. During speed changes (eg
when changing cans), special tuning algorithms
ensure a constant high uniformity of the sliver.

Four synchronized adjustment systems ensure perfect

tape title consistency and excellent uniformity.
Short period adjustment

Regulated feeding of the CONTIFEED card

(eg SP-F feeding cylinder)

adjustment
integrated in
feeder
of flakes

Long-term adjustment

Trützschler Tape Technology

28
 quality supervision

Quality control, online and permanent The TC On request, quality management can every meter of
03 is the first card equipped with comprehensive also be supported by other systems card ribbon is
integrated quality monitoring. Each meter of and tools: controlled
card sliver is checked before depositing it in the
can. The sensor provides the signals for the - The NEPCONTROL TC-NCT nep sensor
survey: permanently transmits the amount of neps,
trash particles and seed husk fragments
- ribbon title, online (see page 38).
- tape uniformity, - The LENGTHCONTROL TC-LCT fiber length
- of the spectrogram, measuring device allows for exact fiber length
- the incidence of thick stitches. measurements (see page 42).

The interpretation of sensor signals takes place in - With the waste sensor WASTECONTROL TC-
the control of the cards and the results are WCT and a special evaluation unit, simple
displayed on the control monitor screen as, for waste optimization is possible (see page 44).
example, spectrogram. On deviation above certain
pre-set limits, the card is automatically switched off. - Quality data can be transmitted over a high
This permanent online control of production is performance network to Barco's superior
superior to sample control in the laboratory. Thick Tape Information System KIT.
stitch monitoring has been integrated into the card
control for the first time.

Presentation of the evaluation of thick stitches on the command Example of a spectrogram on the card screen
screen

Monitor-Ausdruck Monitor-Ausdruck Tape Technology Trützschler

29
 computer command

micro-command Comprehensive quality and production New operating and display panel The basis of
computerized supervision The TC 03 card is controlled using the the new operating and indicating devices is the
reliable most modern computing technique. The control color display with an integrated touch screen. It
records and monitors the relevant data from the forms the interface between the card control
tuft feed, the card as well as the can changer, the and the machine operator, maintenance
settings and the integrated draw frame IDF. personnel and the technical assistance
specialist.

operating devices and

operating levels Operation and display possibilities of indication

Symbols, images,
machine operator Operation specific to schematics, 3 keys
production fixed, few softkeys

settings
maintenance personnel

comfortable indications
Parameter definition
and comprehensive in

different languages +
production management softkeys for
fault finding
different categories
of access

Visualization and indication of

Specialist of
Dice
assistance
technique

All types of operation are recorded on the screen

New operating and display concept – clear In the event of a failure, the point of its location is
structure for simple operation The use of the identified. Simultaneously, the presentation of the
monitor screen means that, when communicating detail image or a schematic with the identification
with the machine operator, there is the possibility of the corresponding fault occurs.
of full use of symbols, diagrams or photographs,
independent of the local language.
In combination with the touch screen, it is
possible to make available only the operating
functions required for each situation.

The new display has, in addition to the screen, only three more keys

Trützschler Tape Technology

30
Simple, language-
independent schematics and
symbols inform the operator
of machine status

Visual information through

photographs or graphics is
often clearer than text
messages (eg in fault
messages)

Quality values are clearly

represented

Tape Technology Trützschler

31
 Added value packages

Greater flexibility Get more value from TC 03 different, there is no difficulty in adapting it to
The TC 03 Trützschler card processes all fibers up this situation in an optimal way.
to 60 mm in length. In its default configuration, it With this in mind, a series of special packages has been
has been optimized for most applications. For created for the TC 03, in order to meet the most extreme
special applications, it is possible to make use of requirements:
the constructive flexibility of the cards and carry
out quick adaptations. These adaptations are easily
interchangeable elements, maintaining the basic
flexibility. If the TC 03 has to temporarily card a
fiber

economy package

Package
Package High
of the fine thread production

Package
Package
optimization of synthetic fiber

The flexibility of the TC 03 can be increased through pre-defined packages

1. The fine yarn package

For yarn titers less than Ne 40 (15 tex) on the dressing table.

2. The synthetic fiber package For

all types of synthetic fibers.

3. The high production package

For card productions > 100 kg/h in an OE rotor spinning mill.

4. The economic package

For waste, electrical energy and faster maintenance.

5. The optimization package

For more comfortable maintenance and faster optimization in flexible application.

Trützschler Tape Technology

32
 TC-FS fine wire pack

Possibility of optimization on the dressing table prepared, a high-density, tighter-fitting flat trim For fine wire
The dressing table places special demands on the can be chosen. Additional carding segments spinning
card. It is not the extremely high production that is equipped with high-density clothing in the post-
at issue. The focus is much more on nep carding area cause more lines in the web. This
separation and good short fiber values. results in higher parallelism of the fibers in the
tape.
The fibers used are longer and the cotton is This package contains, in addition to the standard
often more sensitive. For this reason, the configuration, cleaning elements and carding elements
drum rotation is lower. Even so, to obtain of three different titles.
reduced values of neps, a good pre-carding is
necessary. for fibers well

In the pre-carding area, 3 carding elements are used, each In the post-carding area, 6 carding segments with 12
with 2 clothing strips and 3 cleaning elements clothing strips are used in connection with 3
cleaning elements

1 Kardierelement mit zwei Garniturstreifen

twoReinigungselement
3 Abdeckelement

Tape Technology Trützschler

33
 TC-MS Synthetic Fiber Bundle

For all synthetic Synthetic fibers impose special requirements In viscose carding, few carding segments are
fibers Polyester carding is different than viscose or applicable (6 + 4), for polyester, otherwise, a
polyacrylic carding. However, many spinning mills greater number (7 + 6) are applicable and for
need to process a wide range of the most different polyacrylic, the maximum number (8 + 8).
synthetic fibers. To serve them, a highly flexible Undoubtedly, the card can also be equipped
synthetic fiber package was assembled. with the elements of this package for all
It contains the elements for every synthetic fiber blends.
imaginable type of synthetic fiber:
- The first cylinder of the WEBFEED pre-
opening unit is equipped with rigid gaskets.
- The fiber conducting elements in the tuft
feeder are stainless steel.
- Additionally, carding elements between 90
and 640 points/in two.

For a maximum pre-opening, eg. when processing In the post-carding area, 8 carding elements of
polyacrylic, 8 carding segments with 16 clothing strips are staggered density are displayed
provided in the pre-carding area

The fiber conducting components in the tuft feeder

are stainless steel.
1 Kardierelement mit zwei Garniturstreifen
Trützschler Tape Technology twoReinigungselement
3 Abdeckelement
34
 TC-HS high production package

Extremely high productions require to abrasion. Additional carding segments in the For rotor spinning
special solutions pre- and post-carding area lighten the drum and machine
Extremely high yields place special demands on flat clothing to allow high yields. Compared to
abrasion resistance and lifetime stability. the standard, this pack contains 3 carding
elements and 2 additional cleaning elements.
High productions are permanent capacities above
100 kg/h; what is currently happening in cotton
processing in rotor spinning mills. These
capabilities place special demands on the trim. For
this reason, only gaskets made of resistant special
steels are recommended here.

The arrangement of elements in the pre-carding area is A better post-opening is effected by 6 carding
modified from the default configuration segments equipped with high density clothings

Tape Technology Trützschler

35
 TC-ES economic package

Less waste and 0.5% less total waste on the card

lower consumption of The quality of the waste on the card can be
electricity optimized through special measures in the area
of pre-carding. In addition to the carding and
cleaning elements, 2 control elements are used.
With the aid of an additional fan, these elements
provide modified air conduction over the drum
surface.
The result is immediately visible, there are less
good fibers in the residues of the cleaning
elements for the same cleaning effects.

The TC-ES package is only

possible in connection
with the TC-HS high
production package This additional fan modifies the behavior of the air in the
pre-carding area. The result means less fiber in the waste

Savings of US$ 150.- per year in compressed

air consumption
A special compressor for low pressures is part of the
supply of this package. To keep the fiber ribbon sensor
at its outlet clean, the card only needs 0.4 bar
compressed air. Removing this small pressure from the
compressed air system from the wiring is
uneconomical. With the small special compressor
already installed, it is possible to save more than US$
150.- in compressed air costs per card, already
considering the electricity consumption and the
maintenance of the compressor.

This special small compressor significantly reduces

compressed air costs

No waiting times for cleaning and

maintenance
In order not to wait, depending on the drum
rotation, for up to 20 minutes until the drum stops
after turning off the machine, the card is equipped
with an electronic drum brake, free from abrasion.
The drum stops after only 1 to 2 minutes of braking
time and the doors are unlocked. This saves
valuable time for maintenance specialists and
increases card availability. The material supplied in
this package already includes the additional carding
and cleaning elements of the high production
package.

Electronic drum brake stops the drum in one to two

minutes

Trützschler Tape Technology

36
 TC-OS Optimization Pack

comfort and precision Get the best out of

This package contains a number of additional every application
equipment and auxiliary means that allow for
faster card optimization. This optimization is
mainly necessary in test and pilot series
machines. It is also very suitable for processing a
wide spectrum of raw materials in a card plant.

- Motor adjustment of the PFS precision flat

adjustment system
The two adjustment levers of the PFS system
were replaced by servomotors. The flats This servo motor adjusts the distance from the flats to the drum

adjustment can now be pre-selected on the card

monitor screen and modified while the machine For the optimal adjustment
of the waste volume, a small
is in motion. servomotor adjusts the
- PMS Precision Knife Adjustment System circular knife in relation to
the center of the first
Motor Tuning
WEBFEED cylinder
Here a servomotor is also used. The adjustment
takes place from the monitor screen.
- Linear adjustment of drum rotation
The drum drive motor is controlled by a
frequency regulator. The desired drum
rotation can be continuously selected on the
card screen. The facility is a great help in
constant material changes. This device is also
of great value, for example, to compensate for
the wear of the drum clothing by rotating the Frequency regulator
developed by Trützschler for
drum a little more and thus keeping the level
driving the drum and the
of neps stable. WEBFEED pre-opening unit

- Linear adjustment of WEBFEED rotations The

motor of the three opening cylinders of the WEBFEED
is also controlled by a frequency regulator, which
makes it possible, when necessary, to change the
rotation of the WEBFEED independently of the
rotation of the drum. The setting values of the PFS
and PMS systems, as well as the rotation of the drum
and cylinder of the WEBFEED, related to the start of
material, can be stored in the first memory of the
control. This ensures an extremely short passage
from one material to another.

- Online nep control

The NEPCONTROL TC-NCT nep sensor is also
part of this package. Changes to the settings
can be immediately checked for their influence
on the level of neps. (see page 38).

Neps are supervised online with the

NEPCONTROL TC-NCT nep sensor

Tape Technology Trützschler

37
 NEPCONTROL TC-NCT

card ribbons Control of neps online with perfection Only Controlled nep level
with quality Trützschler offers, with the NEPCONTROL TC- An electronic camera permanently records
proven NCT nep sensor, a real alternative to expensive images of the veil below the peeling cylinder.
laboratory tests. TC-NCT supervises the card The camera runs across the entire working width of the
web during production and provides card on a special, fully enclosed profile. This optical
information regarding its quality. principle has the best correlation with human visual
perception and is therefore superior to the indirect
High-cost laboratory trials were measurement process.
suppressed. Every meter of card sliver is of The high-performance computer mounted directly
proven quality. on the profile interprets the images in relation to
neps, trash particles and cones.

The sensor is mounted below the peeling cylinder The neps sensor is simply mounted on the card using a telescopic guide

two

1
1 camera lens
twoflash equipment
two

The mini camera and special lighting devices move behind the glass and
photograph the veil
Trützschler Tape Technology

38
Reliable data for quality management. experiences in online nep counting with a small
NEPCONTROL TC-NCT can basically be used in investment.
two ways: In the second case, the objective itself, the
permanent monitoring of each card, is achieved. In
- temporary test, with one NEPCONTROL TC- this case it also makes sense to define quality
NCT per card group standards. If these standards are exceeded, the
- permanent test, with a NEPCONTROL TC-NCT corresponding card is turned off. With the
on each card NEPCONTROL NCT it is possible to establish a
distribution (profile) of the level of neps and
In the first case, the test equipment is installed on particles by the working width, which makes it
each card for a few hours (eg for one shift). This possible to immediately detect any damage to the
process makes it possible to make the first clothings.

The high-performance processor takes over the data from This is how the neps values are displayed on the card screen
the digital camera and performs image processing.

NEPCONTROL data has multiple Data transmission to the upper system Of

applications course, it is possible to transmit the measured
The data from the NEPCONTROL TC-NCT nep sensor values to Barco's superior Tape Information
provides quality management with a series of System KIT, which allows for a long-term and
references: trend analysis for quality management.

- Control data on previous processes With these data correlations can be made eg. in
(cleaning line) and raw materials relation to the raw material, the time of use of
- Data on the carding process in progress the trim or the climate. These are important
- Data for a preventive quality control, aiming data for quality optimization.
the yarn
Equipment provided:
- Neps sensor, including processor
- Assembly set, including special software
per card

Tape Technology Trützschler

39
 FLATCONTROL TC-FCT

exact fit and Exact and reproducible flat adjustments With - Improved card sliver quality through
flats goal the flat measuring system FLATCONTROL TC- reduced fit tolerances
FCT, Trützschler offers a system for fast and - Increase in the service life of the gaskets
accurate measuring of the drum / flats distance. - Quick adjustment of flats
Better card sliver quality and longer clothing life - Reproducible, objective and trackable adjustments
are the main advantages of the system: - Flexible use on the Trützschler DK 803, DK 903
and TC 03 cards
- Does not react to interference from personnel

two 1

During measurement, three normal flat rods are A sensor measures, on each side, the distance to the drum
replaced by one measuring flat
1 distance sensor
twoCarbide pins slide over plastic flex bow tape

Measurement across the entire range of flats all measured values. After recording a series of
For measurement, three normal flat rods are measurements, the values are transferred to a PC
replaced by the FLATCONTROL. Sensors in the and displayed graphically.
measuring flat register the distance to the drum
clothing as the measuring flat moves across the
working area. The microprocessor in the flat
rods automatically memorizes

The measuring rod of the

FLATCONTROL system on the
machine

Trützschler Tape Technology

40