TL;DR
Flat strip loss or flat alignment faults are usually a broken flat chain link, a worn flat guide rail, or flat tip damage. Inspect the flat chain and guide rail before replacing individual strips.
What you might see
- flat alignment alarm on the machine controller
- visible gap in the flat strip row
- flat strip jamming at the bend rollers
- increased nep count after flat alignment alarm
Likely causes
Broken or stretched flat chain link allowing flat strips to skip position
Worn flat guide rail causing flat strips to run at an angle to the cylinder
Flat tip (clothing face) damaged from contact with cylinder wire during a wrap event
Flat cleaning brush worn, leading to fiber buildup that jams flat movement
Required tools
- Flat chain link tool
- Replacement flat chain link or full chain
- Flat guide rail inspection gauge
- Wire hook inspection magnifier
- Replacement flat cleaning brush
Safety first
- The flat chain is under tension and can release energy if a link is cut while the chain is taut. Use the flat drive release procedure before working on the chain.
- Lock out the flat drive motor before reaching into the flat running area.
Procedure
- 1
Stop the machine and acknowledge the flat alignment fault on the controller.
- 2
Lock out the flat drive motor.
- 3
Inspect the flat chain at the tension end and the drive end for broken or extended links. Replace the damaged link or the full chain if more than one link is damaged.[1]
- 4
Run the flat travel slowly by hand (manually by rotating the flat drive sprocket) and feel for binding or clicking. A bind point indicates a guide rail damage or a stuck flat strip.
- 5
Inspect the flat guide rail for wear grooves or damage. Replace the guide rail section if wear depth exceeds 0.5 mm.[1]
- 6
Inspect the clothing face of each flat strip near the fault location. Replace any flat with bent or collapsed wire hooks.
- 7
Inspect the flat cleaning brush and replace it if the bristles are worn below the minimum depth.
- 8
Restart the flat drive at low speed, confirm all flats travel without binding, then resume production.
Sources
Trützschler Trützschler TC 19i Carding Machine general technical documentation, Trützschler
Trutzschler TC 19i carding machine general flat system maintenance procedures (general)
More guides for Trützschler Trützschler TC 19i
How to fix card sliver unevenness on a Trutzschler TC 19i carding machine
Sliver unevenness is most often a flat gauge drift, a wire clothing wear, or a doffer speed change. Check the flat-to-cylinder gauge and wire condition before adjusting the autoleveler.
How to fix fiber wrapping on the cylinder or doffer of a Trutzschler TC 19i
Fiber wraps are usually caused by static buildup in low-humidity conditions, worn wire hooks that fail to release fiber, or a sudden change in feed fiber type. Stop and clear the wrap before damage occurs to the wire.
Stop fixing the same fault twice.
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