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
