Cage ultra-long roller brush, special tool and manufacturing method

Abstract

The application belongs to the field of industrial cleaning equipment, and particularly relates to a cage type super-long roller brush, a special tool and a manufacturing method, wherein the roller brush comprises: a hyperboloid roller brush core (1) which is fixedly connected by a shaft head (101), a shaft tail (102), round steel bundles (103) and a rice-shaped support (104); each round steel in the round steel bundles (103) is arranged in a circumferential array with the rotation shaft (2) of the roller brush as a central shaft, and the axis of each round steel in the round steel bundles (103) is in a non-planar straight line relationship with the rotation shaft (2); a bristle module (3) which comprises a mounting plate (301) and bristles (302) fixedly connected to the mounting plate (301), and the bristle module (3) is detachably mounted on the rice-shaped support (104) through fasteners. The application can realize lightweight, high rigidity, easy maintenance and high-precision dynamic balance of the roller brush.

Description

Technical Field

[0001] This invention belongs to the field of industrial cleaning equipment, specifically relating to cage-type extra-long roller brushes, special tooling, and manufacturing methods. Background Technology

[0002] In the industrial cleaning industry, large-area cleaning is often required. In this case, extra-long roller brushes are needed for cleaning. The traditional method for this type of roller brush is to use a steel pipe as the central axis, with a plastic bristle layer with bristle holes on the outside. Finally, the bristles for cleaning are inserted into the bristle holes reserved in the bristle layer, and then the steel pipe and the bristle layer are fixed together. Dynamic balancing tests are performed as needed. This traditional roller brush has many drawbacks. (1) It is too heavy and the bristle ratio is too small. For example, a roller brush with an effective bristle length of more than 5m weighs nearly 200kg, while the bristles used for cleaning weigh less than 15kg. (2) If the amount of bristle shedding is large after a period of use, the entire roller brush has to be scrapped. Other intact parts cannot be repaired or reused, resulting in serious waste. (3) Due to the installation process, there must be a gap between the bristle layer and the central steel pipe for assembly. However, the existence of this gap will affect the dynamic balance accuracy of the roller brush and the reliability in subsequent use. In conclusion, the performance of traditional roller brushes is unsatisfactory, and a new roller brush is urgently needed to replace them. Summary of the Invention

[0003] The present invention aims to overcome the shortcomings of the prior art by providing a cage-type ultra-long roller brush, special tooling and manufacturing method, so as to achieve lightweight, high rigidity, easy maintenance and high-precision dynamic balance of the roller brush.

[0004] To solve the above-mentioned technical problems, the present invention is implemented as follows:

[0005] A cage-type extra-long roller brush, comprising:

[0006] The hyperboloid roller brush core is composed of a shaft head, a shaft tail, a bundle of round steel bars, and a star-shaped support. Each round steel bar in the bundle is arranged in a circular array with the rotation axis of the cage-type ultra-long roller brush as the central axis, and the axis of each round steel bar in the bundle is in a straight line relationship with the rotation axis.

[0007] A bristle module, comprising a mounting plate and bristles fixed thereon, wherein the bristle module is detachably mounted on the star-shaped support by fasteners.

[0008] Furthermore, the star-shaped support is welded from flat steel, wherein the number of flat steel is equal to the number of round steel in the round steel bundle, and they are distributed circumferentially along the axis of rotation.

[0009] Furthermore, the round steel bundle contains 8 round steel bars; the cross-shaped support contains 8 flat steel bars.

[0010] Furthermore, the star-shaped support is provided with a structure for installing dynamic balancing counterweights.

[0011] A special tooling for manufacturing the above-mentioned cage-type extra-long roller brush includes:

[0012] Tooling base, used to support and fix the shaft tail of the roller brush;

[0013] The tooling column is vertically fixed to the tooling base;

[0014] A top cover that can be indexed, rotated, and raised is movably mounted on the tooling column for clamping and driving the roller brush shaft head to rotate and rise.

[0015] Furthermore, the indexable, rotatable, and height-adjustable top cover includes:

[0016] The indexing device is used to drive the shaft head to rotate around the rotation axis and can accurately display and lock the rotation angle;

[0017] A vertical walking device is used to drive the indexable, rotatable, and liftable top cover to move vertically along the tooling column and position it.

[0018] Furthermore, the rotation angle of the handle is proportional to the rotation angle of the indexing plate.

[0019] Furthermore, the ratio of the handle rotation angle to the indexing plate rotation angle is 10:1.

[0020] A method for manufacturing a cage-type extra-long roller brush using the aforementioned special tooling includes the following steps:

[0021] S01: Fix the shaft tail onto the tooling base;

[0022] S02: Temporarily fix one end of the round steel bundle to the shaft tail, and temporarily fix the shaft head to the other end of the round steel bundle;

[0023] S03: Operate the indexable, rotatable, and lifting top cover to clamp the shaft head, and drive the shaft head to rotate to a predetermined angle and lock it through the locking device on the vertical travel device;

[0024] S04: Weld the shaft tail, round steel bundle and shaft head together in the locking position to form a roller brush core skeleton;

[0025] S05: Weld a cross-shaped support onto the roller brush core skeleton;

[0026] S06: Remove the welded roller brush core from the fixture and then install the brush module.

[0027] Compared with the prior art, the present invention has the following characteristics:

[0028] (1) Significant weight reduction: The present invention adopts a hollow cage structure to replace the traditional solid steel pipe, which significantly reduces weight while ensuring rigidity. For example, the total weight of a 5-meter long roller brush can be controlled at around 150 kg, while the weight of the brush bristles is increased to more than 30 kg, and the weight ratio of the brush bristles is significantly improved.

[0029] (2) Easy to maintain and cost-saving: The bristles adopt a modular design, and can be replaced individually after partial damage, avoiding the overall scrapping and greatly reducing maintenance costs.

[0030] (3) High rigidity and high dynamic balance accuracy: The hyperboloid structure has excellent mechanical properties. It completely eliminates the influence of the gap between the bristle layer and the central steel pipe of the traditional roller brush on the dynamic balance. By installing counterweights on the cross support, the dynamic balance adjustment can be more convenient and accurate, and the operation can be more stable.

[0031] (4) High manufacturing precision: Special tooling ensures the precise position of the round steel in space, providing a guarantee for manufacturing high-precision hyperboloid roller brush cores. Attached Figure Description

[0032] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. The scope of protection of the present invention is not limited to the descriptions below.

[0033] Figure 1 This is a schematic diagram showing the completed state of the bristle module of the present invention being installed on the roller brush core;

[0034] Figure 2 This is a schematic diagram of the overall structure of the hyperboloid roller brush core of the present invention;

[0035] Figure 3 This is a schematic diagram showing the state of the top cover of the present invention after it has been installed and rotated to a specified angle.

[0036] Figure 4 This is a partial schematic diagram of the state after the round steel bar and the roller brush shaft tail of the present invention are installed and rotated to a specified angle.

[0037] Figure 5 This is a schematic diagram of several optional structural forms of the cross-shaped support of the present invention.

[0038] In the diagram: 1. Hyperboloid roller brush core; 101. Shaft head; 102. Shaft tail; 103. Round steel bundle; 104. Star-shaped support; 2. Rotating shaft; 3. Brush module; 301. Mounting plate; 302. Brush bristles; 4. Dynamic balance counterweight; 5. Tooling base; 6. Tooling column; 7. Top cover that can be indexed, rotated, and raised; 701. Indexing device; 7011. Handle; 7012. Indexing plate; 702. Vertical travel device; 7021. Traveling wheel. Detailed Implementation

[0039] The following is in conjunction with the appendix Figures 1-5 The principles and features of the present invention are described herein, and the examples given are for illustrative purposes only and are not intended to limit the scope of the invention. The invention is described more specifically in the following paragraphs by way of example with reference to the accompanying drawings. The advantages and features of the invention will become clearer from the following description and claims. It should be noted that the drawings are in a very simplified form and use non-precise proportions, and are only used to facilitate and clarify the illustration of the embodiments of the invention. It should be noted that when a component is referred to as being "fixed to" another component, it can be directly on the other component or there may be an intervening component. When a component is considered to be "connected to" another component, it can be directly connected to the other component or there may be an intervening component. When a component is considered to be "disposed on" another component, it can be directly disposed on the other component or there may be an intervening component. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to limit the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0040] like Figures 1-5 As shown, a cage-type extra-long roller brush includes:

[0041] The hyperboloid roller brush core 1 is formed by a shaft head 101, a shaft tail 102, a round steel bundle 103, and a star-shaped support 104. Each round steel in the round steel bundle 103 is arranged in a circular array with the rotation axis 2 of the roller brush as the central axis, and the axis of each round steel in the round steel bundle 103 is in a straight line relationship with the rotation axis 2.

[0042] The brush module 3 includes a mounting plate 301 and brush bristles 302 fixed thereon. The brush module 3 is detachably mounted on the star-shaped support 104 by fasteners.

[0043] See Figure 2 and Figure 5 As shown, the cross-shaped support 104 of the present invention is welded from flat steel, and its number is equal to the number of round steel in the round steel bundle 103, and they are distributed circumferentially along the rotation axis 2.

[0044] The round steel bundle 103 of the present invention contains 8 round steel bars; the cross-shaped support 104 contains 8 flat steel bars. The cross-shaped support 104 is provided with a structure for installing the dynamic balance counterweight 4.

[0045] See Figure 3 , Figure 4As shown, the special tooling for manufacturing the above-mentioned cage-type extra-long roller brush includes:

[0046] Tooling base 5, used to support and fix the shaft tail 102 of the roller brush;

[0047] The tooling column 6 is vertically fixed to the tooling base 5;

[0048] The indexable, rotatable, and height-adjustable top cover 7 is movably mounted on the tooling column 6 and is used to clamp and drive the roller brush shaft head 101 to rotate and lift.

[0049] See Figure 3 As shown, the indexable, rotatable, and height-adjustable top cover 7 includes:

[0050] Indexing device 701 is used to drive the shaft head 101 to rotate around the rotating shaft 2, and can accurately display and lock the rotation angle;

[0051] The vertical walking device 702 is used to drive the indexable, rotatable, and liftable top cover 7 to move vertically along the tooling column 6 and to position it.

[0052] See Figure 3 As shown, the indexing device 701 includes a handle 7011 and an indexing plate 7012. The rotation angle of the handle 7011 is proportional to the rotation angle of the indexing plate 7012. The ratio of the rotation angle of the handle 7011 to the rotation angle of the indexing plate 7012 is 10:1.

[0053] The invention features a top cover that can be indexed, rotated, and raised / lowered, ensuring precise spatial positioning and welding of round steel bars and solving the precision problem in manufacturing ultra-long parts.

[0054] See Figure 3 , Figure 4 As shown, the method for manufacturing a cage-type extra-long roller brush using the above-mentioned special tooling includes the following steps:

[0055] S01: Fix the shaft tail 102 onto the tooling base 5;

[0056] S02: Temporarily fix one end of the round steel bundle 103 to the shaft tail 102, and temporarily fix the shaft head 101 to the other end of the round steel bundle 103;

[0057] S03: The top cover 7, which can be indexed, rotated and raised, clamps the shaft head 101, and drives the shaft head 101 to rotate to a predetermined angle and then locks it.

[0058] S04: Weld the tail 102, the round steel bundle 103 and the head 101 at the locking position to form a roller brush core skeleton;

[0059] S05: Weld a cross-shaped support 104 onto the roller brush core skeleton;

[0060] S06: Remove the welded roller brush core from the fixture and then install the brush module 3.

[0061] In its specific design, the cage-type extra-long roller brush of this invention is assembled from a hyperboloid roller brush core and plate-type bristles using fasteners. The hyperboloid roller brush core of this invention is mainly composed of round steel, a star-shaped support 104, a shaft head 101, and a shaft tail 102, all welded together. The brush core consists of multiple round steel bars forming a round steel bundle 103, each round steel bar arranged in a circumferential array with the rotating shaft 2. When the roller brush rotates along the rotating shaft 2, the movement trajectory of all the round steel bars is the same single-leaf hyperbola. The star-shaped support 104 is made of flat steel welded around the rotating shaft. The number of flat steel bars is the same as the number of round steel bars; in this example, both round steel bars and flat steel bars are 8. As the roller brush shaft diameter increases or decreases, the number of round steel bars and flat steel bars increases or decreases accordingly. The star-shaped support 104 serves not only as support between the round steel bars of the brush core but also as the mounting point for the plate-type bristles. A dynamic balance weight 4 can also be welded to it, achieving multiple functions in one. The shaft head 101 and shaft tail 102 are machined from steel, a simple process that will not be described in detail here. The bristle module 3 consists of a mounting plate 301 and bristles 302, a mature product on the market, and will not be described in detail here. The special tooling in this invention mainly consists of a tooling base 5, a tooling column 6, and a top cover 7 that can be indexed, rotated, and raised. The tooling base 5 supports the entire tooling and serves to fix the roller brush during the manufacturing process. It is made of sheet metal or steel and is parallel to the ground. The tooling column 6 is made of profile and is responsible for guiding and fixing the top cover 7 that can be indexed, rotated, and raised in the vertical direction. It has graduations and is perpendicular to the ground. The top cover 7 that can be indexed, rotated, and raised can slide up and down along the slide rails on the tooling column 6 via the traveling wheels 7021. The top cover 7 that can be indexed, rotated, and raised is the key part of the entire tooling. It mainly consists of an indexing device 701 and a vertical traveling device 702. The indexing device 701 can rotate along the rotating shaft 2, while displaying and fixing the rotation angle. For precise adjustment of the rotation angle, the rotation angle of the handle 7011 is proportional to the rotation angle of the indexing plate 7012 (set to 10:1 in this example). The vertical travel device 702 can move up and down along the tooling column and also has a positioning function on the tooling column. The indexable, rotatable, and liftable top cover 7 is equipped with a speed-changing gear mechanism. The power output end of the handle 7011 transmits power to the speed-changing gear mechanism, which then transmits the power to the power output end of the indexable, rotatable, and liftable top cover 7. A clamp is provided at the power output end of the indexable, rotatable, and liftable top cover 7 for clamping the shaft head 101. Figures 1 to 5As shown, the core of the present invention lies in the hyperboloid roller brush core. This brush core is welded by a shaft head 101 and a shaft tail 102 made by turning steel, a round steel bundle 103, and multiple cross-shaped supports 104. The round steel bundle 103 is evenly arranged in a circumferential array centered on the rotation axis 2, and the axis of each round steel is in a skew line state with the rotation axis 2, that is, neither intersecting nor parallel. The multiple cross-shaped supports 104 are welded into a "cross" shape by flat steel, and its eight endpoints are respectively welded to each round steel of the round steel bundle 103, and are distributed at intervals of about 1 meter along the circumferential direction. Counterweight blocks 4 can be welded on the cross-shaped supports 104 for dynamic balance correction. The brush hair module 3 is composed of a mounting plate 301 and brush hairs 302 planted thereon, and is fixed on the cross-shaped support 104 by bolts.

[0062] When making a cage-type ultra-long roller brush, the following steps are required:

[0063] The first step: Place the special tooling base 5 on the horizontal ground, and install the tooling column 6 on the tooling base 5, perpendicular to the ground.

[0064] The second step: Place the shaft tail 102 of the roller brush on the tooling base 5 of the tooling.

[0065] The third step: Install the round steel bundle 103 and the shaft head 101.

[0066] The fourth step: Install the top cover 7 that can be indexed for rotation and lifting.

[0067] The fifth step: Rotate the top cover 7 that can be indexed for rotation and lifting, so that the shaft head 101 rotates and带动 the round steel to rotate.

[0068] The sixth step: After rotating to the specified angle, first fix the top cover 7 that can be indexed for rotation and lifting on the tooling. Then weld the shaft tail 102, the round steel bundle 103, and the shaft head 101 of the roller brush together.

[0069] The seventh step: Install the cross-shaped support 104 at the designed position and weld it to the round steel bundle 103. Complete the manufacture of the roller brush core.

[0070] The eighth step: Remove the roller brush core from the tooling, and install the brush hair module 3 on the brush core through fasteners.

[0071] Although the embodiments of the present invention have been shown and described, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirits of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A cage-type extra-long roller brush, characterized in that, include: The hyperboloid roller brush core (1) is formed by connecting the shaft head (101), shaft tail (102), round steel bundle (103) and cross-shaped support (104); each round steel in the round steel bundle (103) is arranged in a circular array with the rotation axis (2) of the cage-type ultra-long roller brush as the central axis, and the axis of each round steel in the round steel bundle (103) is in a straight line relationship with the rotation axis (2); The brush module (3) includes a mounting plate (301) and brush bristles (302) fixed thereon. The brush module (3) is detachably mounted on the star-shaped support (104) by fasteners.

2. The cage-type extra-long roller brush according to claim 1, characterized in that: The cross-shaped support (104) is welded from flat steel, wherein the number of flat steel is equal to the number of round steel in the round steel bundle (103), and they are distributed circumferentially along the rotation axis (2).

3. The cage-type extra-long roller brush according to claim 2, characterized in that: The round steel bundle (103) contains 8 round steel bars; the cross-shaped support (104) contains 8 flat steel bars.

4. The cage-type extra-long roller brush according to claim 3, characterized in that: The cross-shaped support (104) is provided with a structure for installing dynamic balance counterweights (4).

5. A special tooling for manufacturing the cage-type extra-long roller brush as described in any one of claims 1 to 4, characterized in that, include: Tooling base (5) is used to support and fix the shaft tail (102) of the roller brush. The tooling column (6) is vertically fixed to the tooling base (5); A top cover (7) that can be indexed, rotated and raised is movably mounted on the tooling column (6) for clamping and driving the shaft head (101) of the roller brush to rotate and rise.

6. The special tooling for the cage-type ultra-long roller brush according to claim 5, characterized in that: The indexable, rotatable, and height-adjustable top cover (7) includes: Indexing device (701) is used to drive the shaft head (101) to rotate around the rotating shaft (2) and can accurately display and lock the rotation angle; A vertical walking device (702) is used to drive the indexable, rotatable, and lifting top cover (7) to move vertically and position along the tooling column (6).

7. The special tooling for the cage-type ultra-long roller brush according to claim 6, characterized in that: The indexing device (701) includes a handle (7011) and an indexing plate (7012), wherein the rotation angle of the handle (7011) is proportional to the rotation angle of the indexing plate (7012).

8. The special tooling for the cage-type ultra-long roller brush according to claim 7, characterized in that: The ratio of the rotation angle of the handle (7011) to the rotation angle of the indexing plate (7012) is 10:

1.

9. A method for manufacturing a cage-type extra-long roller brush using the special tooling as described in claim 5, characterized in that, Includes the following steps: S01: Fix the shaft tail (102) onto the tooling base (5); S02: Temporarily fix one end of the round steel bundle (103) to the shaft tail (102), and temporarily fix the shaft head (101) to the other end of the round steel bundle (103); S03: The top cover (7) that can be indexed, rotated and raised is used to clamp the shaft head (101), and the shaft head (101) is driven to rotate to a predetermined angle and then locked by the locking device on the vertical walking device (702); S04: The shaft tail (102), round steel bundle (103) and shaft head (101) are welded together in the locking position to form a roller brush core skeleton; S05: Weld a cross-shaped support (104) onto the roller brush core skeleton. S06: Remove the welded roller brush core from the tooling and then install the brush bristle module (3).

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