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<i>For Its High-Production Card DK 903</i>

With the introduction of the High-Production Card DK 903, Trutzschler, Germany, has once again set new standards for carding machines.The high-production card DK 903 is the further development of Trutzschlers most successful card, the DK 803. More than 5,000 DK 803s have been installed in spinning mills all over the world since its initial introduction at ITMA 95.The new DK 903, with its additionally implemented high-tech features, will improve carding quality even more. All technological and production factors considered, the DK 903 is the most exciting short-staple fiber card we have seen being introduced in this century. Profile Of A BestsellerEven though visually unnoticeable, the DK 903 adds a long list of new and improved features compared to the DK 803. However, most of the core elements that made the 803 such a sales success remain (almost) unchanged.The 803 offered, as the first card, an integrated direct feeding system that consisted of the chute, the integral feed plate Sensofeed and the three-licker-in mat preparation system Webfeed. Further, on all main functions AC servo drives were installed, aluminum flats which are guided by toothed belts were a first in carding, and on-line quality monitoring was integrated.The new features of the 903 are mainly concentrated in following areas: Improvements in setting the card to closest tolerances for carding; Reduction of maintenance and adjustment times; Significant improvement of quality on-line monitoring; and Integrated sliver drawing zone (optional). Powerhouse DK 903Feeding of the fibers starts with Directafeed, the tuft feeder that is an integral part of the 903. From there the Sensofeed, a 10-segmented feed plate releases the fibers to the first licker-in of the Webfeed opening rollers.The Webfeed three-roll system consists of three relatively small opening/licker-in rollers, which are not by design revolutionary, but because of their small size and tangential extraction force they can imply. This results in better trash and small particle removal.This three-roll configuration allows a gradual acceleration of the fibers towards the high surface speed of the main cylinder by simultaneously orientating the fibers properly and removing impurities effectively. Therefore, the transfer of the fibers from the last licker-in roller to the cylinder through a pre-prepared fiber mat is better than trough conventional one-licker-in systems.The fibers then travel past the up to 10 Twin Top stationary carding segments, pass the suction supported mote knives and enter the revolving flat section.This is the area where the 903 really shows several new technology features. Flats/Cylinder InteractionThe optimum interaction of cylinder and flats is the most important factor for cleaning and nep reduction. The new Trutzschler Flatconcept takes this into account.The individual flat bars are made of aluminum profiles, light and at the same time extremely rigid. They are guided by two toothed belts without special fastening elements; the flats are basically just simply laying on the belts. A full flat exchange can be done by only one person, and in less than an hour. There is no oiling or greasing, and the whole flat area remains clean and maintenance-free.Stepless controllable drive allows the exact adaptation of the flat speed to the processed material. The new flat cleaning device allows extended service intervals.The most important setting on a card to target the sliver/yarn quality is the precise distance of the flats to the cylinder. The Flatcontrol FCT was designed for objective distance measurement. A flat with electronic measuring devices measures exactly the distance to the cylinder to the flats, static or in motion. The computer print-out of the measurements of the Flatcontrol system is a very useful tool for effective quality management.The Precision Flat Setting PFS is a new and patented system from Trutzschler to set flats with high-precision, reproducible, and without tools. The 903 is equipped with a manual centralized flat-adjustment mechanism, or, the customer can order the motorized option. Either way, the adjustments that took hours before can be literally executed in seconds.Also new is the Precision Flat Grinding System PCS for technologically correct touch-ups of the flats. Trutzschler emphasizes that this procedure is far away from the conventional grinding process and only used to make small touch-ups when the quality control system indicates this. This ensures optimum performance of the card over the entire card-wire life.Actual quality control during production is achieved with the optional nep sensor Nepcontrol NCT that Trutzschler offers as an alternative to off-line laboratory testing. NCT monitors the card web for neps and trash during production with reports on on-line quality, instead of random laboratory sampling. NCT works on an optical/visual measuring principle that delivers meaningful data to Trutzschlers SliverNCT can be permanently installed on each card, or, for cost saving reasons, it can be used as a transferable unit within card groups.On the 903, all dedusting and cleaning points are under direct and continuous suction. This guarantees best possible trash removal with constant cleaning efficiency and keeps the environment clean. The 903 also features a high-speed can coiler/changer KHC that was developed for speeds up to 400 m/min.Brand new for the 903 is the optional Integrated Drawframe IDF. It is especially promising for specific open-end yarn applications.Trutzschler emphasizes that not every final yarn application has been tested so far. However, initial results show that elimination of one drawing process is possible, the overall machinery investment is lower, and the space savings reflect investment cost positively. And, there are many other positive effects that will make spinning mills look very carefully at the IDF system in the future.Needless to say, the 903 offers all the bells and whistles of ocmputer control through its Cardcommander. The Cardcommander collects production data and monitors all function groups of the machine. An on-line display can retrieve machine settings, quality data, statistical data and much more. Success With GuaranteeBased on the sales success of the DK 803 Trutzschler is almost certain that the DK 903 will continue its success story.Trutzschler officials confirmed that customers all around the world show great interest in this new card. Achievable mill productions are claimed to be beyond 100 kg/hr. (~220 lbs./hr) The quality consistency, the cost savings and a fast return on investment will almost guarantee the success of the Innovation Award winning DK 903.

November 1999