Needling mechanism, needling machine and needle changing method for an automotive carpet

Abstract

The present invention discloses a needling mechanism, a needling machine and a method for replacing needles of an automotive carpet, mainly relating to the field of carpet needling. It includes a pressing plate assembly and a needle plate assembly with an up-and-down lifting stroke; the needle plate assembly includes a mounting frame, a pressing plate, a quick-installation plate and a barbed needle. The pressing plate is located below the mounting frame and its height position relative to the mounting frame is adjustable. The quick-installation plate is hinged to the mounting frame. Equally spaced strip-shaped grooves are provided on the quick-installation plate. A strip-shaped through hole corresponding to its length direction is provided in the center of the bottom of the strip-shaped groove. The width of the strip-shaped through hole is adapted to the diameter of the barbed needle. A rectangular block corresponding to the width of the strip-shaped groove is provided at the top of the barbed needle. The top surface of the rectangular block is located above the opening of the strip-shaped groove. The bottom surface of the pressing plate is in contact and cooperation with the top surface of the rectangular block. The pressing plate assembly has a flat plate below the barbed needle, and a needle hole is provided at the installation position of the flat plate corresponding to the barbed needle. The beneficial effect of the present invention is that the installation and maintenance of the barbed needle are more labor-saving, fast, and the fixation is reliable and firm.

Description

Technical Field

[0001] The present invention relates to the field of carpet needling, and specifically to a needling mechanism, a needling machine and a method for replacing needles of an automotive carpet. Background Art

[0002] Needled carpets are a major category of automotive carpets. They are economical and applicable, with a high market share, and occupy the mainstream in mid - to - low - grade automotive supplies. They include PET needled carpets, composite needled carpets, etc. Regardless of how the materials and layers of the structural surface layer are combined, the main processing process of them cannot do without forming the material layer by needling the fibers.

[0003] For example, fibers such as polypropylene and polyester fiber, after being opened and carded, form a fiber web. The fiber web is laid into multiple layers by a lapping machine and then needled to obtain a material layer. If it is a composite carpet, the material layers made of multiple layers of fibers with different materials may be laminated. For example, in an existing production line of composite carpets in our company, the adopted process includes:

[0004] (1) Open and mix polyester fibers evenly; convey them to a carding machine through a cotton storage box for carding to form a fiber web; convey the fiber web to a lapping machine to lay it into multiple layers of fiber webs; then convey the multiple - layer fiber webs to a needling machine for needling to make a fabric layer; the needling depth of the needling machine is 5 - 8 mm and the speed is 5 - 8 m / min; convey the fabric layer to a raising machine for raising; the pile height of the raising is 5 - 7 mm, and the pile density of the raising is 500 - 700 needles per square centimeter;

[0005] (2) Open and mix polypropylene fibers and low - melting - point fibers in a preset weight ratio evenly; convey them to a carding machine through a cotton storage box for carding to form a fiber web; convey the fiber web to a lapping machine to lay it into multiple layers of fiber webs; then convey the multiple - layer fiber webs to a needling machine for needling to make a base layer; the needling depth of the needling machine is 5 - 10 mm and the speed is 3 - 5 m / min;

[0006] (3) Melt polyethylene at a high temperature, and bond the surface layer in step (1) and the base layer in step (2) together on a film laminating machine, and the melting temperature is 250 - 300 °C;

[0007] (4) After the surface layer and the base layer are compounded, penetrate the non - ventilated PE film in the middle through a needling machine to form a ventilated state (the ventilated state requires adjusting the specification model and needling surface density of the piercing needle) to improve the sound absorption performance of the base layer.

[0008] (5) Finally, a layer of PE film is coated on the base layer through a film laminating machine, then wound into a roll and cut to obtain the corresponding carpet sheet products.

[0009] The produced automotive carpet has a surface layer of flocked felt, a base layer of PET, an intermediate PE film lamination, and a bottom layer structure for waterproofing and sound insulation. It can be seen that in the production process, the fiber material needs to be needled repeatedly, so the needling process is very important.

[0010] The core components of the needling machine are the needle plate and the needles. The needling machine uses needles with a triangular or other shaped cross-section and barbs on the edges to repeatedly pierce the fiber web. When fed into the needling machine, the fiber web is very fluffy and only has a certain strength generated by the cohesion between fibers, but the strength is very poor. When multiple needles pierce the fiber web, the barbs on the needles will drive the fibers on the surface and subsurface of the fiber web to move from the plane direction of the fiber web to the perpendicular direction of the fiber web, causing the fibers to shift up and down. The fibers that shift up and down will exert a certain pressure on the fiber web, causing the fibers in the fiber web to come closer and be compressed, forming the surface layer. Therefore, the key to this process lies in the quality of needling. In actual production, in order to obtain a surface layer with uniform thickness, tightness, and firmness, it is necessary to regularly clean the fiber on the needle plate and replace the broken needles, because the fibers hooked between the needles will hinder the penetration amplitude and strength, and the existence of broken needles will cause the surface of the surface layer to be uneven and may have needle marks, directly affecting the product quality. For composite products with lamination, it will also directly affect the quality of the lamination process.

[0011] In normal workshop production, our maintenance cycle for the needle plate is very frequent. The cleaning work is carried out at any time according to needs, and the broken needles need to be checked and replaced every two weeks. According to the process requirements, the number of needles on a needle plate may vary from 2000 to 8000. All these needles need to be manually disassembled and installed by knocking. It is very time-consuming and laborious. Moreover, since the broken needle situation can only be observed by the naked eye, it is very easy to miss the inspection and replacement, and the process quality cannot be guaranteed. Summary of the Invention

[0012] The purpose of the present invention is to provide a needling mechanism, a needling machine, and a needle replacement method for automotive carpets, which are more labor-saving, fast, and have reliable and firm fixation for the installation and maintenance of needles.

[0013] To achieve the above object, the present invention is realized through the following technical solutions:

[0014] A needling mechanism for automotive carpets includes a pressing plate assembly and a needle plate assembly with an up-and-down lifting stroke;

[0015] The needle plate assembly includes a mounting frame, a pressing plate, a quick-installation plate, and needle pins. The pressing plate is located below the mounting frame and its height position relative to the mounting frame is adjustable. The quick-installation plate is located below the pressing plate and is hinged to one side of the mounting frame. A row of strip-shaped grooves are equidistantly provided on the quick-installation plate. The openings of the strip-shaped grooves face upward and are rectangular grooves. A strip-shaped through hole corresponding to its length direction is centrally provided at the bottom of the strip-shaped groove. The width of the strip-shaped through hole is adapted to the diameter of the needle pin. A rectangular block corresponding to the width of the strip-shaped groove is provided at the top end of the needle pin. The top surface of the rectangular block is located above the opening of the strip-shaped groove. The bottom surface of the pressing plate is in contact with the top surface of the rectangular block. The pressing plate assembly has a flat plate below the needle pins, and needle holes adapted to the diameter of the needle pins are provided at the installation positions of the needle pins corresponding to the flat plate.

[0016] A rectangular frame opening adapted to its size is provided on the mounting frame. The pressing plate corresponds to the size of the frame opening. Mounting beams are equidistantly provided along the length direction of the mounting frame on the frame opening. Mounting holes are provided on the mounting beams. A plurality of fastening screws are provided on the top surface of the pressing plate corresponding to the mounting holes. The fastening screws penetrate through the mounting holes and are fitted with fastening nuts.

[0017] Wing plates are respectively provided on both sides of the quick-installation plate. Columns are provided on the wing plates. A knob is eccentrically provided at the top end of the column. One end of the knob is rotatably sleeved on the top end of the column. The length of the knob is greater than the distance between the column and the side of the frame, and the bottom surface of the knob is a flat surface, and this flat surface is flush with the top surfaces on both sides of the frame.

[0018] The needle plate assembly further includes a placeholder block. The placeholder block is a rectangular square block with a width corresponding to the width of the strip-shaped groove. The height of the placeholder block is lower than that of the rectangular block.

[0019] A sinking channel is provided at the long side of the mounting frame away from the side hinged to the quick-installation plate. The length of the sinking channel is adapted to the mounting frame. The inner and outer side walls of the sinking channel are guiding surfaces inclined inward at the bottom end. A pressing block is provided in the sinking channel. The inner side surface and the outer side surface of the pressing block are inclined surfaces parallel to and in contact with the guiding surfaces. A vertical pushing surface is provided at the bottom of the inner side surface of the pressing block. The pushing surface is used to contact the rectangular block or the placeholder block located at the outermost end of the strip-shaped groove. A plurality of U-shaped grooves are provided on the top surface of the pressing block. The U-shaped grooves are semi-through grooves communicating with the outside of the pressing block. Small screws located in the U-shaped grooves are provided on the guiding surface on the outside. Small nuts are fitted on the small screws.

[0020] It further includes an auxiliary component that cooperates with the needle plate component; the strip-shaped groove is a semi-channel, and the strip-shaped groove is provided with a through port at the outer end of the quick-installation plate away from the hinged position. The auxiliary component includes a vertical plate, the inner end face of the vertical plate is used to contact the outer side edge of the quick-installation plate, a plug block is provided at the top side of the vertical plate corresponding to each strip-shaped groove, the plug block is movably inserted into the through port, limiting strips are provided on both sides of the vertical plate, convex plates that cooperate with the limiting strips are respectively provided on the left and right sides of the quick-installation plate. When the bottom surface of the plug block contacts the bottom of the strip-shaped groove, the bottom surface of the convex plate contacts the top surface of the limiting strip. A support plate that can adjust its position along the height direction is provided at the bottom side of the vertical plate, and the support plate is located below the tip of the acupuncture needle.

[0021] A support frame is provided at the bottom side of the vertical plate, a support plate perpendicular to the vertical plate is provided above the support frame, guide rods are respectively provided at the four corner positions of the support plate, guide holes corresponding to the guide rods on the same side are provided on the support frame, the guide rods penetrate through the guide holes and are in clearance fit with the guide holes. A large screw rod is rotatably connected to the center of the bottom surface of the vertical plate, a screw sleeve corresponding to the large screw rod is provided at the center of the support frame, the large screw rod is threadedly connected to the screw sleeve, and a handle is provided at the bottom end of the large screw rod.

[0022] Pin holes are respectively provided on the limiting strips and the convex plates. When the plug block contacts the rectangular block or the placeholder block at the outermost end of the strip-shaped groove, the pin holes on the limiting strips and the pin holes on the convex plates are vertically aligned. A pin rod is penetrated and fitted in the pin holes, and the pin rod is L-shaped.

[0023] Above the pressing plate component, a main shaft and a cross beam are arranged side by side up and down. A transmission belt pulley is provided at one end of the main shaft. A guide sleeve penetrating up and down is installed on the cross beam. A transmission belt pulley is provided at one end of the main shaft. Cam modules are respectively provided at positions near both ends of the main shaft. Two eccentric wheel modules are symmetrically installed in the middle of the main shaft.

[0024] The cam module includes a cam disk group fixedly installed on the main shaft. The cam disk group is eccentrically installed relative to the main shaft. The cam disk group is composed of two cam disks with a relatively symmetrical structure. A wheel groove is provided on the inner end face of the cam disk. The wheel groove is a closed loop-shaped wheel groove and is arranged around the main shaft in a circle. One end of the wheel groove is close to the axis of the main shaft and the other end is far from the axis of the main shaft. The end of the wheel groove far from the main shaft is the a section, and the a section is an arc coaxial with the main shaft. A pressing plate guide rod is provided below the cam disk group. The top end of the pressing plate guide rod is provided with an installation piece inserted upward between the two cam disk groups. A hanging shaft penetrates through the top end of the installation piece. Roller wheels that are symmetrically installed at both ends of the hanging shaft and are matched with the wheel groove are provided in the wheel groove. A circular retaining piece is provided at one end of the roller wheel close to the installation piece. The diameter of the retaining piece is larger than the width of the wheel groove opening. The bottom ends of the pressing plate guide rods are respectively fixed at both ends of the pressing plate component.

[0025] The eccentric wheel module includes an eccentric disk installed and fixed on the main shaft, the eccentric disk is eccentrically penetrated by a shaft sleeve, the shaft sleeve is installed with the main shaft by a key connection, the outer sleeve of the eccentric disk is connected with an outer wheel disk, a circular disk cavity coaxial with the outer wheel disk is provided in the outer wheel disk, the thickness of the disk cavity is adapted to the thickness of the eccentric disk, the eccentric disk is located in the disk cavity, the disk cavity is provided with a circular clearance opening in its eccentric area, the shaft sleeve passes through the clearance opening, a sealing ring is fixed on the peripheral side of the outer wheel, an articulated arm is fixed on the bottom side of the sealing ring, the bottom end of the articulated arm is hinged with a needle plate guide rod, the bottom end of the needle plate guide rod is fixed to the mounting frame, the pressure plate guide rod and the needle plate guide rod are respectively light rod guide rail structures, the pressure plate guide rod and the needle plate guide rod respectively pass through the guide sleeves at corresponding positions and are slidably connected with the guide sleeves.

[0026] A needling machine comprises a body, wherein the above-mentioned needling mechanism is installed in the body, a motor is installed on one side of the body, a power pulley is fixed on the output shaft of the motor, and a belt is wound between the power pulley and the transmission pulley.

[0027] A needle replacement method comprises the following steps:

[0028] Flip the quick release plate downward;

[0029] Insert the needle through the strip-shaped through hole and insert the rectangular block into the strip-shaped groove. If there is a broken needle, pull the broken needle upward and out of the strip-shaped groove;

[0030] Flip the quick release plate upward until it is parallel to the mounting frame and secure it.

[0031] Compared with the prior art, the beneficial effects of the present invention are:

[0032] After the improvement of this technology, flexible arrangement and adjustment of the needles can be achieved. After the needles are arranged on the quick-release plate, the pressing plate is used to press the needles down on the quick-release plate, so that the needles can be fixed quickly, labor-savingly and reliably. There is no need to insert the needles into the needle eyes and knock the needles one by one, and they are not easy to loosen during production. The fixation is reliable, firm and effective. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a front schematic diagram of the acupuncture mechanism of the present invention.

[0034] Figure 2 It is a schematic diagram of the acupuncture mechanism of the present invention.

[0035] Figure 3 It is a schematic diagram of the disassembly of the components of the acupuncture mechanism of the present invention.

[0036] Figure 4 It is a schematic diagram of the internal structure of the cam module of the present invention.

[0037] Figure 5 It is a schematic internal structure diagram of the eccentric wheel module of the present invention.

[0038] Figure 6 It is a schematic structural diagram of the needle plate assembly of the present invention.

[0039] Figure 7 It is a schematic diagram of the component disassembly of the installation frame of the present invention at the position of the sinking channel.

[0040] Figure 8 It is a schematic side sectional view of the needle plate assembly of the present invention.

[0041] Figure 9 It is a schematic diagram of the cooperation between the needle plate assembly and the auxiliary assembly of the present invention.

[0042] Figure 10 It is a schematic bottom view of the cooperation between the needle plate assembly and the auxiliary assembly of the present invention.

[0043] Figure 11 It is the present invention Figure 9 Enlarged view of part I.

[0044] Figure 12 It is the present invention Figure 10 Enlarged view of part II.

[0045] Figure 13 It is a side view of the cooperation between the needle plate assembly and the auxiliary assembly of the present invention.

[0046] Figure 14 It is a schematic structural diagram of one end of the quick mounting plate of the present invention.

[0047] Reference numerals shown in the drawings:

[0048] 1. Support beam; 2. Bearing seat; 3. Main shaft; 4. Belt pulley; 5. Cross beam; 6. Guide sleeve; 7. Cam disc; 8. Groove; 9. Roller; 10. Retaining piece; 11. Mounting piece; 12. Pressing plate guide rod; 13. Eccentric disc; 14. Bush; 15. Outer disc; 16. Relief opening; 17. Hinge arm; 18. Needle plate guide rod; 19. Pressing plate assembly; 20. Flat plate; 21. Mounting frame; 22. Pressing plate; 23. Quick mounting plate; 24. Stitch needle; 25. Rectangular block; 26. Occupying block; 27. Mounting beam; 28. Fastening screw; 29. Fin; 30. Column; 31. Knob; 32. Strip groove; 33. Strip through hole; 34. Sinking channel; 35. Guide surface; 36. Pressing block; 37. Pushing surface; 38. U-shaped groove; 39. Small screw; 40. Vertical plate; 41. Support frame; 42. Support plate; 43. Guide rod; 44. Large screw; 45. Nut sleeve; 46. Handle; 47. Plug; 48. Limit strip; 49. Convex plate; 50. Pin rod. Detailed implementation manners

[0049] The present invention will be further described below in conjunction with specific embodiments. It should be understood that these embodiments are only used to illustrate the present invention and not to limit the scope of the present invention. In addition, it should be understood that after reading the content taught by the present invention, those skilled in the art can make various changes or modifications to the present invention, and these equivalent forms also fall within the scope defined by this application.

[0050] Embodiment 1: A needling mechanism and a needle loading method for an automotive carpet

[0051] In production, the top priority in the management of the needling process is the timely and high-quality maintenance of the needle plate. However, this work is difficult to quantify. Due to the excessive work intensity, the staff often complain. Moreover, the long-term troubleshooting leads to visual fatigue, making it difficult to detect broken needles 100%. Once there are individual missing eyes, it will cause problems with the bonding quality of the laminated sheet in this area. These are all quality hidden dangers that affect the product life, but they are difficult to screen out during quality inspection, bringing a quality black hole to product control.

[0052] This improvement mainly realizes a qualitative leap in the maintenance and replacement of the needle plate through the improvement of the needling machine. The main structure of the needling machine includes a machine body (for the convenience of showing the internal structure, the frame is not shown in the drawings).

[0053] The machine body is a metal shell structure for protecting the internal components.

[0054] A needling mechanism is installed inside the machine body.

[0055] The needling mechanism includes a support beam 1 located at the upper part and a cross beam 5 located in the middle. The upper support beam 1 and the cross beam 5 are respectively fixedly installed inside the machine body to provide fixed positions for the installation of the internal transmission mechanism.

[0056] There are multiple support beams 1, which are arranged along the transverse direction of the fiber web. A bearing seat 2 is fixed on the support beam 1, and a main shaft 3 passes through the bearing seat 2. The main shaft 3 is horizontally arranged and its length direction is perpendicular to the conveying direction of the fiber web. The main shaft 3 is located above the cross beam 5 and they are arranged side by side vertically.

[0057] One end of the main shaft 3 is provided with a transmission pulley 4. A motor is installed on the machine body, and a power pulley is fixed on the output shaft of the motor. A belt is wound between the power pulley and the transmission pulley 4 to realize belt transmission of the rotation of the motor and the rotation of the main shaft 3.

[0058] Cam modules are respectively provided at positions near both ends of the main shaft 3, and two eccentric wheel modules are symmetrically installed in the middle of the main shaft 3.

[0059] The cam module includes 7 groups of cam disks fixedly installed on the main shaft 3. The 7 groups of cam disks are eccentrically installed relative to the main shaft 3. The 7 groups of cam disks are two cam disks 7 with a relatively symmetrical structure. A wheel groove 8 is provided on the inner end face of the cam disk 7. The wheel groove 8 is a closed loop-shaped wheel groove 8 and is arranged around the main shaft 3 in a circle. One end of the wheel groove 8 is close to the axis of the main shaft 3 and the other end is far from the axis of the main shaft 3. The end of the wheel groove 8 far from the main shaft 3 is section a, and section a is an arc coaxial with the main shaft 3, so that when the pressing plate is pressed down to the bottom of its stroke, there is a pause in height to maintain the pressing position on the mesh material.

[0060] Below the 7 groups of cam disks, there is a pressing plate guide rod 12. The top of the pressing plate guide rod 12 is provided with an installation piece 11 that is inserted upward between the two groups of cam disks 7. A hanging shaft penetrates through the top of the installation piece 11. At both ends of the hanging shaft, rollers 9 located in the wheel groove 8 and cooperating with the wheel groove 8 are symmetrically installed. A circular retaining piece 10 is provided at one end of the roller 9 close to the installation piece 11. The diameter of the retaining piece 10 is greater than the width of the notch of the wheel groove 8. Through the cooperation of the roller 9 and the wheel groove 8, the pressing plate guide rod 12 can be driven by the 7 groups of cam disks to have an up-and-down movement stroke, which is defined as stroke a for the convenience of description. Stroke a has a pause at the bottom of its stroke.

[0061] The eccentric wheel module includes an eccentric disk 13 installed and fixed on the main shaft 3. An axle sleeve 14 is eccentrically penetrated through the eccentric disk 13. The axle sleeve 14 is installed and fixed to the main shaft 3 through key connection to realize the eccentric installation and fixation of the eccentric disk 13 and the main shaft 3. An outer wheel disk 15 is sleeved outside the eccentric disk 13. A circular disk cavity coaxial with it is provided inside the outer wheel disk 15. The thickness of the disk cavity is adapted to the thickness of the eccentric disk 13. The eccentric disk 13 is located inside the disk cavity. A circular relief opening 16 is provided in the eccentric area of the disk cavity. The axle sleeve 14 penetrates through the relief opening 16, and the relief opening 16 is used to provide a relief space for the rotation of the axle sleeve 14 and the eccentric disk 13. A sealing ring is fixed on the circumferential side of the outer wheel. An articulated arm 17 is fixed on the bottom side of the sealing ring. The bottom end of the articulated arm 17 is hinged to a needle plate guide rod 18.

[0062] Through the cooperation of the eccentric disk 13 and the disk cavity, the driving of the up-and-down movement stroke of the needle plate guide rod 18 is realized, which is defined as stroke b for the convenience of description. Stroke b is a reciprocating lifting stroke.

[0063] In order to constrain and guide the up-and-down movement of the above-mentioned strokes a and b, guide sleeves 6 are respectively installed and fixed through the cross beam 5 corresponding to the pressure plate guide rod 12 and the needle plate guide rod 18. The pressure plate guide rod 12 and the needle plate guide rod 18 are respectively of a smooth rod guide rail structure and have the same diameter, which is convenient for component configuration. The pressure plate guide rod 12 and the needle plate guide rod 18 respectively pass through the guide sleeves 6 at corresponding positions to realize the constraint on the vertical stroke of the pressure plate guide rod 12 and the needle plate guide rod 18.

[0064] Below the cross beam 5, a pressure plate assembly 19 and a needle plate assembly are provided;

[0065] The pressure plate assembly 19 is a sheet metal part, with the structure shown in the figure, obtaining a relatively high-strength support effect. The two ends of the pressure plate assembly 19 are respectively fixedly installed at the bottom ends of the two pressure plate guide rods 12;

[0066] The pressure plate assembly 19 is provided with a flat plate 20 at its bottom. The flat plate 20 is used to uniformly press down the mesh material to assist the needle punching operation. And corresponding to the installation position of each needle 24 on the flat plate 20, there are needle holes (since the needle holes are small and closely arranged, the drawing will form a black block at this part, and this feature can be clearly defined through description, so it is omitted in the attached drawing). The needle holes are used for the needles 24 to pass through. These needle holes are arranged in a matrix on the flat plate 20. When the needles 24 rise and retract, the fibers hooked on the needles 24 can be blocked, thus solving the problem of fiber entanglement in each needle punching link, directly omitting the frequent cleaning operation of the needle plate, and greatly reducing the workload of needle plate maintenance.

[0067] The needle plate assembly includes an installation frame 21, a pressing plate 22, a quick-installation plate 23, needles 24, and a placeholder block 26;

[0068] The installation frame 21 is a metal frame. The installation frame 21 is arranged at the central position above the flat plate 20. The top surface of the installation frame 21 is fixedly installed with the bottom end of the needle punching guide rod. The installation frame 21 rises and falls following the stroke b to complete the needle punching action.

[0069] The installation frame 21 is strip-shaped, and the length direction of the installation frame 21 corresponds to the length direction of the main shaft 3.

[0070] The installation frame 21 is provided with a rectangular frame opening adapted to its size. The frame opening is adapted to the size of the pressing plate 22. The pressing plate 22 is located at the bottom of the frame opening and is used to adjust and quickly fix and press the needles 24. Along the length direction of the installation frame 21, installation beams 27 are equidistantly arranged on the frame opening. There are installation holes on the installation beams 27. Corresponding to the installation holes on the top surface of the pressing plate 22, there are a plurality of fastening screws 28. The fastening screws 28 pass through the installation holes and are matched with fastening nuts. By adjusting the fastening nuts, the pressing degree of the pressing plate 22 on the needles 24 can be adjusted.

[0071] One side of the quick-release plate 23 is hinged to one side of the mounting frame 21 through a shaft, enabling the quick-release plate 23 to be turned downward for opening and closing.

[0072] Wing plates 29 are respectively provided on two sides of the quick-release plate 23 that are relatively rotationally connected. Columns 30 are provided on each of the wing plates 29. The columns 30 are circular columns 30. A knob 31 is rotationally connected to the top of the column 30. The knob 31 is an eccentric knob 31. One end of the knob 31 is rotationally sleeved on the top of the column 30. The length of the knob 31 is greater than the distance between the column 30 and the side of the frame. And the bottom surface of the knob 31 is a plane, and this plane is flush with the top surfaces on both sides of the frame. When the knob 31 rotates to one side of the frame, it can limit the quick-release plate 23 so that it cannot be turned downward. Through the operation of the knob 31, the downward swing of the quick-release plate 23 can be blocked quickly, simply and reliably, which is convenient and fast. And there are two knobs 31 on each side, which is safe and reliable.

[0073] The top of the knob 31 is a cross structure, which is convenient for manual operation and the twisting cooperation of fingers, and is convenient for the hand to exert force.

[0074] Strip-shaped grooves 32 are equidistantly arranged in an array along the length direction of the quick-release plate 23. The strip-shaped grooves 32 are long strip-shaped grooves with a rectangular cross-section. Define the inner end of the strip-shaped groove 32 as the end of the quick-release plate 23 close to the hinge with the mounting frame, and the other end as the outer end.

[0075] A strip-shaped through hole 33 is provided in the middle of the bottom of the strip-shaped groove 32. The width of the strip-shaped through hole 33 is adapted to the diameter of the thorn needle 24. A rectangular block 25 is provided at the top of the thorn needle 24. The width of the rectangular block 25 corresponds to the groove width of the strip-shaped groove 32. The height of the rectangular block 25 is higher than the groove depth of the strip-shaped groove 32, so that the top surface of the rectangular block 25 is exposed above the strip-shaped groove 32 and can cooperate with the bottom surface of the pressing plate 22 to achieve downward pressing and fixing.

[0076] The rectangular blocks 25 can be arranged in an orderly manner in a row in the strip-shaped grooves 32, so as to realize the orderly fixing of the thorn needles 24. Combined with the equidistantly arranged strip-shaped grooves 32, thorn needles 24 with a matrix distribution can be obtained.

[0077] The placeholder block 26 is a rectangular block with a width corresponding to the groove width of the strip-shaped groove 32. The height of the placeholder block 26 is lower than that of the rectangular block 25. Therefore, the bottom surface of the pressing plate 22 can only cooperate with the rectangular block 25 to realize occupying the space only in the length direction of the strip-shaped groove 32, stretching the distance between adjacent thorn needles 24, without affecting the downward pressing of the bottom surface of the pressing plate 22 on the thorn needles 24. The length of the placeholder block 26 is preferably 1 or multiple times the length of the rectangular block 25.

[0078] Considering that different requirements for the arrangement of the acupuncture needles 24 are needed according to different processes and acupuncture at different positions. For example, in the acupuncture of wire mesh into sheets, it is necessary to set up the first, second to multiple acupuncture machines to repeatedly acupuncture, so that the sheet is more compact. And each acupuncture has different requirements for the density and arrangement of the acupuncture needles 24. The current method of installing the needles is to directly open holes on the needle plate and then knock the needles into the holes as needed. After each needle needs to be inserted into the needle hole for alignment, manual hammering is carried out. Moreover, there is a loosening situation during use, making the acupuncture surface uneven. This improvement realizes the occupation of the space in the strip-shaped groove 32 through the occupation block 26, which is convenient and flexible to use, and obtains the acupuncture needle 24 arrays with different layouts.

[0079] On the long side of the installation frame 21 away from the side hinged to the quick-installation plate 23, there is a sunken channel 34. The length of the sunken channel 34 is adapted to the installation frame 21. The two side walls on the length direction of the sunken channel 34 are parallel inclined side walls. The inclined side walls are defined as the guiding surfaces 35, and the bottom side of the guiding surface 35 is inclined inward. There is a pressing block 36 in the sunken channel 34. The inner side surface and the outer side surface of the pressing block 36 are inclined surfaces parallel to the guiding surface 35. The two inclined surfaces on both sides of the pressing block 36 are respectively in contact with the two guiding surfaces 35, so that the pressing block 36 can have a downward and inward moving stroke in the sunken channel 34. At the bottom of the inner side surface of the pressing block 36, there is a vertical pushing surface 37. The pushing surface 37 is used to contact the rectangular block 25 (or the occupation block 26) at the outermost end of the strip-shaped groove 38U. Thus, through the downward pressing of the pressing block 36, the inward advancement of the vertical pushing surface 37 is obtained, and the pushing and tightening of the acupuncture needles 24 along the length direction of the strip-shaped groove 32 are realized, ensuring the tight arrangement of the acupuncture needles 24. On the top surface of the pressing block 36, there are a plurality of U-shaped grooves 38U. The U-shaped grooves 38U are semi-through grooves communicating with the outside of the pressing block 36. On the outer guiding surface 35, there are upright small screws 39 corresponding to the positions of the U-shaped grooves 38U. The small screws 39 penetrate the outer guiding surface 35 and can be disassembled for easy installation. A small nut is fitted on the small screw 39, and the small nut presses against the notch of the U-shaped groove 38U to realize the downward pressing of the pressing block 36 and obtain the strengthening of the tightness of the arrangement of the acupuncture needles 24.

[0080] Based on the above structure, the method for quick installation or adjustment and maintenance of the acupuncture needles 24 is as follows:

[0081] Loosen the small nut and rotate the knob 31 so that the knob 31 leaves the top surfaces on both sides of the installation frame 21;

[0082] Flip the quick-installation plate 23 downward, and the rectangular block 25 is blocked by the outer end of the strip-shaped groove 32;

[0083] Insert the occupation block 26 and the rectangular block 25 of the acupuncture needles 24 into the strip-shaped groove 32 as needed until all the strip-shaped grooves 32 are filled;

[0084] Flip the quick-release plate 23 upward, lift it up so that it is parallel to the mounting frame 21, and rotate the knob 31 so that its bottom surface presses against the top surfaces on both sides of the mounting frame 21;

[0085] Tighten the small nut so that the vertical pushing surface 37 on the inner side of the pressing block 36 presses against and tightly holds the outer surface of the rectangular block 25 at the outermost end of the strip-shaped groove 32;

[0086] Tighten the fastening bolt, and through the pressing plate 22, press downward on the top surfaces of all the rectangular blocks 25 to enhance the fixation of the top surface of the lancet 24.

[0087] Through the above method, based on the setting of the placeholder block 26, the flexible arrangement adjustment of the lancet 24 is realized. Through the strip-shaped groove 32 and the rectangular block 25, a quick arrangement is obtained. After arranging the lancets 24 on the quick-release plate 23, the arrangement of the lancets 24 is pressed by the pressing block 36, and the lancets 24 are pressed downward on the quick-release plate 23 through the pressing plate 22, realizing the quick, labor-saving and reliable fixation of the lancets 24. There is no need for manual labor to insert the needle eyes one by one and knock the needle heads, and it is not easy to loosen during production, and it is convenient to strengthen the downward pressure at any time through the fastening bolt, and the fixation is reliable, firm and effective.

[0088] Embodiment 2: A needling mechanism and a broken needle replacement method for an automotive carpet

[0089] Different from Embodiment 1, the strip-shaped groove 32 is a semi-channel, and the strip-shaped groove 32 is provided with a through port at the outer end of the quick-release plate 23 away from the hinged position, and is also provided with an auxiliary component for assisting in maintaining the lancet 24;

[0090] The auxiliary component includes a vertical plate 40. A support frame 41 is provided at the bottom side of the vertical plate 40. Above the support frame 41, there is a support plate 42 perpendicular to the vertical plate 40. Guide rods 43 are respectively provided at the four corner positions of the support plate 42. Corresponding to the guide rods 43 on the same side on the support frame 41, guide holes are respectively provided. The guide rods 43 penetrate through the guide holes and are in clearance fit with the guide holes, so that the support plate 42 can be kept perpendicular to the vertical plate 40 and slide up and down.

[0091] The bottom surface of the vertical plate 40 is rotatably connected to a large screw rod 44 at the center. A screw sleeve 45 is provided at the center of the support frame 41 corresponding to the large screw rod 44. The large screw rod 44 penetrates through the screw sleeve 45, and a handle 46 is provided at the bottom end of the large screw rod 44. By rotating the handle 46, the distance between the support plate 42 and the support frame 41 can be adjusted.

[0092] At the top side of the vertical plate 40, a blocking block 47 is provided corresponding to each strip-shaped groove 32. The blocking block 47 is movably inserted into the through opening. On both sides of the vertical plate 40, limiting strips 48 are further provided. The limiting strips 48 are fixed perpendicular to the vertical plate 40. On the left and right sides of the quick-installation plate 23, convex plates 49 cooperating with the limiting strips 48 are respectively provided. When the bottom surface of the blocking block 47 contacts the bottom of the strip-shaped groove 32, the bottom surface of the convex plate 49 contacts the top surface of the limiting strip 48. The up-and-down positioning of the auxiliary component in the thickness direction relative to the quick-installation plate 23 is realized.

[0093] Pin holes are respectively provided on the limiting strip 48 and the convex plate 49. When the blocking block 47 contacts the rectangular block 25 or the placeholder block 26 located at the outermost end of the strip-shaped groove 32, the pin holes on the limiting strip 48 and the convex plate 49 are vertically aligned. A pin rod 50 is penetrated and fitted in the pin holes. The pin rod 50 is L-shaped, and the front-and-back position of the auxiliary component relative to the quick-installation plate 23 can be quickly locked.

[0094] The distance from the support frame 41 to the blocking block 47 is greater than the length of the thimble 24. Therefore, after the auxiliary component is positioned on the quick-installation plate 23 through the above structure, the support plate 42 is located below all the thimbles 24. And as the quick-installation plate 23 is turned downwards, the thimble array in the tightly arranged state of the blocking block 47 is not affected by the turning, and the support plate 42 is automatically tilted and adjusted relative to the bottom surface of the thimble 24. At this time, turn the handle 46, the support plate 42 approaches the thimble 24 needle piece and pushes the thimble 24 needle piece towards the flipping plate direction, so that the thimble 24 is pushed up, and the bottom surface of the rectangular block 25 leaves the bottom of the groove by a certain distance while still being located in the strip-shaped groove 32. If there is a broken needle, there will be a non-flat depression on the top surface of the corresponding rectangular block 25, thus clearly reflecting the position of the broken needle. Compared with directly observing whether the tip of the needle is short by a section, the difficulty is greatly reduced. The abnormality of the tip of the needle is instead prominently shown through whether the top surfaces of the rectangular blocks 25 are coplanar. The problem of missed inspection is avoided. At the same time, the broken needle can be directly extracted by pinching the rectangular block 25 at the corresponding depression position, and the spare thimble 24 can be supplemented at the missing position, which is very convenient, labor-saving and fast.

[0095] Based on the above structure, the method for replacing the broken thimble 24 is as follows:

[0096] Insert the blocking block 47 on the vertical plate 40 into the strip-shaped groove 32 corresponding to each through opening. At the same time, align the positions of the limiting strip 48 and the upper convex plate 49. After the vertical plate 40 is correspondingly inserted and fitted outside the quick-installation plate 23, insert the pin rod 50 to relatively position the auxiliary component and the quick-installation plate 23;

[0097] Loosen the small nut and turn the knob 31 so that the knob 31 leaves the top surfaces on both sides of the mounting frame 21;

[0098] Flip the quick-release plate 23 downward, and the rectangular block 25 is blocked by the blocking block 47;

[0099] Rotate the handle 46 until the support plate 42 pushes the needle piece of the needle 24 so that the bottom surface of the rectangular block 25 disengages from the strip groove 32 but does not leave the strip groove 32;

[0100] Observe row by row whether the top surfaces of the rectangular blocks 25 are coplanar. If there are depressions, take out the rectangular blocks 25 at the depression positions and insert the needles 24;

[0101] After the broken needle replacement is completed, flip the quick-release plate 23 upward, lift it to make it parallel to the mounting frame 21, and rotate the knob 31 so that its bottom surface presses on the top surfaces on both sides of the mounting frame 21;

[0102] Remove the pin rod 50 and disassemble the auxiliary component;

[0103] Tighten the small nut so that the vertical pushing surface 37 on the inner side of the pressing block 36 presses and clamps on the outer surface of the rectangular block 25 at the outermost end of the strip groove 32;

[0104] Tighten the fixing bolt, and through the pressing plate 22, press down all the top surfaces of the rectangular blocks 25 to enhance the fixation of the top surfaces of the needles 24.

[0105] Through the above method, the operation of broken needle replacement is labor-saving, fast, and has high maintenance quality, and the problem of missed inspection is solved. The quality of the needle punching process is guaranteed.

Claims

1. A needling mechanism for an automotive carpet, characterized in that, It includes a platen assembly and a needle plate assembly with an up-and-down lifting stroke; The needle plate assembly includes a mounting frame, a pressing plate, a quick-installation plate, and barbed needles. The pressing plate is located below the mounting frame and its height position relative to the mounting frame is adjustable. The quick-installation plate is located below the pressing plate and is hinged to one side of the mounting frame. A row of strip-shaped grooves are equidistantly arranged on the quick-installation plate. The notch of the strip-shaped groove is upward and is a rectangular groove. A strip-shaped through hole corresponding to its length direction is centrally arranged at the bottom of the strip-shaped groove. The width of the strip-shaped through hole is adapted to the diameter of the barbed needle. A rectangular block corresponding to the width of the strip-shaped groove is arranged at the top end of the barbed needle. The top surface of the rectangular block is located above the notch of the strip-shaped groove. The bottom surface of the pressing plate is in contact and cooperation with the top surface of the rectangular block. The platen assembly has a flat plate below the barbed needle. Needle holes adapted to the diameter of the barbed needle are arranged at the installation positions of the barbed needles on the flat plate. A rectangular frame opening adapted to its size is arranged on the mounting frame. The pressing plate corresponds to the size of the frame opening. Mounting beams are equidistantly arranged along the length direction of the mounting frame on the frame opening. Mounting holes are arranged on the mounting beams. A plurality of fastening screws are arranged on the top surface of the pressing plate corresponding to the mounting holes. The fastening screws penetrate through the mounting holes and are matched with fastening nuts. Wings are respectively arranged on both sides of the quick-installation plate. Columns are arranged on the wings. A knob is eccentrically arranged at the top end of the column. One end of the knob is rotatably sleeved on the top end of the column. The length of the knob is greater than the distance between the column and the side of the frame. And the bottom surface of the knob is a plane, and this plane is flush with the top surfaces on both sides of the frame. A sinking channel is arranged at the long side of the mounting frame far from the side hinged to the quick-installation plate. The length of the sinking channel is adapted to the mounting frame. The inner and outer side walls of the sinking channel are guiding surfaces with the bottom ends inclined inward. A pressing block is arranged in the sinking channel. The inner side surface and the outer side surface of the pressing block are inclined surfaces parallel to and in contact with the guiding surfaces. A vertical pushing surface is arranged at the bottom of the inner side surface of the pressing block. The pushing surface is used to contact the rectangular block or the placeholder block located at the outermost end of the strip-shaped groove. A plurality of U-shaped grooves are arranged on the top surface of the pressing block. The U-shaped grooves are semi-through grooves communicating with the outside of the pressing block. Small screws located in the U-shaped grooves are arranged on the guiding surface on the outside. Small nuts are matched with the small screws; A needling mechanism for an automotive carpet further includes an auxiliary assembly that cooperates with the needle plate assembly. The strip-shaped groove is a semi-channel. A through port is arranged at the outer end of the strip-shaped groove on the quick-installation plate far from the hinged position. The auxiliary assembly includes a vertical plate. The inner end face of the vertical plate is used to contact the outer side of the quick-installation plate. A blocking block is arranged on the top side of the vertical plate corresponding to each strip-shaped groove. The blocking block is movably inserted into the through port. Limiting strips are also arranged on both sides of the vertical plate. Convex plates cooperating with the limiting strips are respectively arranged on the left and right sides of the quick-installation plate. When the bottom surface of the blocking block is in contact with the bottom of the strip-shaped groove, the bottom surface of the convex plate is in contact with the top surface of the limiting strip. A support plate capable of adjusting its position along its height direction is arranged at the bottom side of the vertical plate. The support plate is located below the tip of the barbed needle.

2. The needling mechanism of an automotive carpet according to claim 1, characterized in that, The needle plate assembly further includes a placeholder block, which is a rectangular block with a width corresponding to the width of the strip groove, and the height of the placeholder block is lower than that of the rectangular block.

3. The needling mechanism of an automotive carpet according to claim 1, characterized in that, A support frame is provided at the bottom side of the vertical plate. Above the support frame, there is a support plate perpendicular to the vertical plate. Guide rods are respectively provided at the four corner positions of the support plate. Corresponding to the guide rods on the same side of the support frame, there are guide holes respectively. The guide rods penetrate through the guide holes and are in clearance fit with the guide holes. The bottom surface of the vertical plate is rotatably connected to a large screw rod in the center. A screw sleeve is provided at the center of the support frame corresponding to the large screw rod. The large screw rod is threadedly connected to the screw sleeve, and a handle is provided at the bottom end of the large screw rod. and / or Pin holes are respectively provided on the limiting strip and the convex plate. When the plug block contacts the rectangular block or the placeholder block located at the outermost end of the strip groove, the pin holes on the limiting strip and the pin holes on the convex plate are vertically aligned. A pin rod is penetrated and fitted in the pin holes, and the pin rod is L-shaped.

4. The needling mechanism of an automotive carpet according to claim 1, characterized in that Above the pressing plate assembly, there are a main shaft and a cross beam arranged vertically in parallel with it. A transmission belt pulley is provided at one end of the main shaft. A guide sleeve penetrating up and down is installed on the cross beam. Cam modules are respectively provided at positions near both ends of the main shaft. Two eccentric wheel modules are symmetrically installed in the middle of the main shaft. The cam module includes a cam disc group fixedly installed on the main shaft. The cam disc group is eccentrically installed relative to the main shaft. The cam disc group is composed of two cam discs with a relatively symmetrical structure. A wheel groove is provided on the inner side end surface of the cam disc. The wheel groove is a closed loop-shaped wheel groove and is arranged around the main shaft in a circle. One end of the wheel groove is close to the axis of the main shaft and the other end is far from the axis of the main shaft. The end of the wheel groove far from the main shaft is section a, and section a is an arc coaxial with the main shaft. Below the cam disc group, there is a pressing plate guide rod. The top end of the pressing plate guide rod is provided with an installation piece inserted upward between the two cam disc groups. A hanging shaft penetrates through the top end of the installation piece. At both ends of the hanging shaft, rollers located in the wheel groove and matched with the wheel groove are symmetrically installed. A circular retaining piece is provided at one end of the roller close to the installation piece. The diameter of the retaining piece is larger than the width of the wheel groove opening. The bottom ends of the pressing plate guide rods are respectively fixed at both ends of the pressing plate assembly. The eccentric wheel module includes an eccentric disc installed and fixed on the main shaft. A bushing is eccentrically penetrated through the eccentric disc. The bushing is installed and connected to the main shaft by a key. An outer wheel disc is sleeved outside the eccentric disc. A circular disc cavity coaxial with it is provided inside the outer wheel disc. The thickness of the disc cavity is adapted to the thickness of the eccentric disc. The eccentric disc is located inside the disc cavity. A circular relief opening is provided in the eccentric area of the disc cavity. The bushing penetrates through the relief opening. A sealing ring is fixed on the circumferential side of the outer wheel. An articulated arm is fixed at the bottom side of the sealing ring. The bottom end of the articulated arm is articulated with a needle plate guide rod. The bottom end of the needle plate guide rod is fixed to the installation frame. The pressing plate guide rod and the needle plate guide rod are respectively of a smooth rod guide rail structure. The pressing plate guide rod and the needle plate guide rod respectively penetrate through the corresponding guide sleeves and are slidably connected with the guide sleeves.

5. A needle punching machine, characterized in that, It includes a fuselage, and the needling mechanism as described in any one of claims 1-4 is installed inside the fuselage.

6. A method for changing needles, characterized in that, A method for installing and replacing the acupuncture needles of the acupuncture mechanism according to any one of claims 1-4, comprising the following steps: Flip the quick-installation plate downward; Pass the acupuncture needle through the strip-shaped through-hole, and insert the rectangular block into the strip-shaped groove. If there is a broken needle, take out the broken needle upward from the strip-shaped groove; Flip the quick-installation plate upward until it is parallel to the installation frame and fix it.

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