Needle matching mechanism and operation method thereof

Abstract

The needle matching mechanism comprises a frame body, a plurality of material distributing units, a material collecting unit and a control unit, the material distributing units are all located on the upper portion of the material collecting unit, and the material distributing units communicate with the material collecting unit; the material distributing units, the material collecting unit and the control unit are all installed on the frame body. By integrating a plurality of independently adjustable distributing units and a plurality of uniformly confluence collecting units, efficient, orderly and synchronous matching of needle bodies of multiple varieties and specifications is achieved, manual needle distributing and needle loading are replaced, the efficiency is improved, and meanwhile the problem that manual needle distributing is prone to making mistakes is solved. The falling needle group is actively combed and buffered through the needle setting wheel mechanism, then the needle passes through the needle passing channel capable of being accurately adjusted, and finally stable separation and rhythmic sending-out of single needles are achieved through the needle rolling disc mechanism, so that the problems that long and thin needle bodies are prone to clamping stagnation, accumulation, mutual hooking, damage and the like in the automatic conveying process are solved, and the production efficiency is improved. And the continuity and the reliability of the needle separating process are ensured.

Description

A needle-dispensing mechanism and its operating method Technical Field

[0001] This invention relates to the field of needle fitting machine technology, specifically a needle fitting mechanism and its operating method. Background Technology

[0002] In fields such as medical devices, textiles and apparel, and precision instrument manufacturing, it is often necessary to mix and combine needles of various specifications. Traditional manual needle mixing methods are inefficient and inconsistent, while existing automated equipment can usually only process needles of a single specification, making it difficult to meet the production needs of mixing multiple types of needles. When different specifications of needles need to be processed simultaneously, multiple machines often need to operate in parallel, and then be combined manually or with auxiliary devices, resulting in a complex system structure, large footprint, and difficulties in coordinated control.

[0003] Furthermore, due to the slender shape of the needles, they are prone to disordered arrangement, snagging, or jamming during conveying, affecting operational stability and needle integrity. When switching needle specifications, existing equipment often requires cumbersome mechanical adjustments or even component replacements to key parameters such as the conveying channel and dispensing rhythm. This inconvenient and time-consuming adjustment process restricts production flexibility and rapid changeover capabilities. Summary of the Invention

[0004] The purpose of this invention is to provide a needle fitting mechanism and its operation method that can flexibly adapt to needles of different specifications, achieve stable and orderly single needle separation and delivery, and efficiently integrate and converge multiple needle flows, so as to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a needle distribution mechanism, comprising a frame, a plurality of distributing units, a collecting unit, and a control unit, wherein the plurality of distributing units are all located above the collecting unit, and the distributing units are connected to the collecting unit; the plurality of distributing units, the collecting unit, and the control unit are all mounted on the frame.

[0006] As a further embodiment of the present invention: the material distribution unit includes a fixed frame, a feeding mechanism, a needle-stopping plate mechanism, a needle-shifting wheel mechanism, and a needle roller mechanism; the fixed frame is detachably disposed from the frame body; the feeding mechanism, the needle-shifting wheel mechanism, and the needle roller mechanism are installed sequentially from top to bottom within the fixed frame; the needle-stopping plate mechanism acts within the feeding mechanism, and the needle-stopping plate mechanism is connected to both the feeding mechanism and the fixed frame.

[0007] As a further aspect of the present invention: the material collection unit includes an upper material collection hopper, a lower material collection hopper, and a needle outlet, wherein the upper material collection hopper is detachably connected to the frame; the upper material collection hopper, the lower material collection hopper, and the needle outlet are connected sequentially from top to bottom, and the upper material collection hopper and the lower material collection hopper are detachably connected, wherein the lower material collection hopper and the needle outlet are an integral structure.

[0008] As a further embodiment of the present invention: the feeding mechanism includes a material box, a material box seat, a front needle-passing plate with an arc-shaped groove on the upper part, a rear needle-passing plate, and a needle-passing channel; the material box is located on the upper part of the material box seat, and the material box is connected to the material box seat; both the material box and the material box seat are detachably set to the fixed frame; both the front needle-passing plate and the rear needle-passing plate are located inside the material box seat, and a needle-passing channel is formed between the front needle-passing plate and the rear needle-passing plate; both the front needle-passing plate and the rear needle-passing plate are adjustablely set to the material box seat; the material box includes a needle-collecting chamber and a needle-dispensing chamber, the needle-dispensing chamber is located between the needle-collecting chamber and the material box seat, the bottom of the needle-collecting chamber and the bottom of the needle-dispensing chamber are inclined towards the material box seat, and the needle-collecting chamber and the needle-dispensing chamber are an integral structure.

[0009] As a further embodiment of the present invention: the needle-blocking plate mechanism is located directly above the needle-dispensing chamber and the material box seat; the needle-blocking plate mechanism includes a support frame, a needle-blocking plate, a through-hole, and an adjusting handle with a screw at the lower end; the support frame is located at the upper end outside the material collection chamber, and the support frame is detachably connected to the fixed frame; the needle-blocking plate is located inside the material collection chamber, and the needle-blocking plate is located at the lower end of the support frame, and the needle-blocking plate is slidably connected to the material collection chamber; the through-hole is opened in the middle of the support frame, and the adjusting handle is threadedly engaged with the needle-blocking plate through the through-hole, and the adjusting handle is rotatably engaged with the support frame; through the adjusting handle and the needle-blocking plate, the channel between the material collection chamber and the needle-dispensing chamber can have two states: open and closed.

[0010] As a further embodiment of the present invention: the needle-shifting wheel mechanism includes a needle-shifting shaft, a needle-shifting part, a first rotary motor, a first motor base, two first synchronous pulleys, and a first synchronous belt; the needle-shifting shaft is located in an arc-shaped groove on the upper part of the front needle-passing plate, and one end of the needle-shifting shaft is rotatably connected to the inside of the fixed frame, while the other end of the needle-shifting shaft passes through the fixed frame and is located outside the fixed frame; the portion of the needle-shifting shaft located on the upper part of the front needle-passing plate fixes the needle-shifting part; the first rotary motor is mounted inside the fixed frame via the first motor base, and the rotating end of the first rotary motor passes through the fixed frame and is located outside the fixed frame; both the needle-shifting shaft end located outside the fixed frame and the rotating end of the first rotary motor are fixed to the first synchronous pulleys; the first synchronous belt is sleeved on the two first synchronous pulleys.

[0011] As a further embodiment of the present invention: the needle roller mechanism includes a needle roller shaft, a needle roller disc, a second rotary motor, a second motor mount, two second synchronous pulleys, and a second synchronous belt; the needle roller shaft is located at the lower part of the needle passage, and one end of the needle roller shaft is rotatably connected to the inside of the fixed frame, while the other end of the needle roller shaft passes through the fixed frame and is located outside the fixed frame; the portion of the needle roller shaft located at the lower part of the needle passage fixes the needle roller disc; the second rotary motor is mounted inside the fixed frame via the second motor mount, and the rotation point of the second rotary motor passes through the fixed frame and is located outside the fixed frame; the second synchronous pulleys are fixed at one end of the needle roller shaft and the rotation end of the second rotary motor located outside the fixed frame; the second synchronous belt is sleeved on the two second synchronous pulleys.

[0012] As a further aspect of the present invention: the control unit is electrically connected to the first rotary motor and the second rotary motor, and the control unit includes a control panel and a display panel, both of which are detachably mounted to the frame.

[0013] As a further embodiment of the present invention: pressure plates are provided at both ends of the bottom of the front needle plate and the rear needle plate, and the pressure plates are detachably connected to the material box seat. Spring grooves are provided at both ends of the upper part of the rear needle plate, and springs are provided in the spring grooves. The front needle plate and the rear needle plate are movably connected to the material box seat through the springs.

[0014] The present invention also provides an operating method for a needle distribution machine as described in any of the preceding claims, comprising the following steps: S1: Adjusting the relative position between the front needle guide plate and the rear needle guide plate in the dispensing unit according to the current specifications of the needles to be dispensed, so as to form a needle passage matching the needle specifications; adjusting the needle baffle mechanism to control the flow rate of needles entering the material box seat from the needle collection chamber; S2: Placing the needles into the needle collection chamber of the feeding mechanism; setting operating parameters including the rotation speed of the first rotary motor and the second rotary motor through the control unit; S3: Starting the equipment, the control unit controls the first rotary motor to drive the needle-picking part to rotate, rhythmically pushing the needles from the material box seat into and through the needle passage, buffering and sorting the falling needles; the control unit controls the second rotary motor to drive the needle roller to rotate, the needle roller receiving the needles falling from the needle passage and rhythmically feeding them into the collection unit below in a single form; S4: Needles of different specifications output from each dispensing unit are collected in the collection unit and finally discharged uniformly from the needle outlet.

[0015] Compared with existing technologies, the beneficial effects of this invention are as follows: By integrating multiple independently adjustable dispensing units and a unified converging collection unit, this invention achieves efficient, orderly, and synchronous proportioning of multiple types and specifications of needles, replacing manual needle dispensing and loading, improving efficiency while solving the problem of errors easily encountered in manual needle dispensing. This device integrates the mixed needle dispensing task that previously required multiple machines into one unit, significantly simplifying the production line layout and improving space utilization and production flexibility. Furthermore, this device actively sorts and buffers the falling needle group through a needle-gathering wheel mechanism, and then, through a precisely adjustable needle passage, finally achieves smooth separation and rhythmic delivery of individual needles by a needle roller mechanism. This solves the problems of jamming, accumulation, mutual hooking, and damage that easily occur in the automated conveying of slender needles, ensuring the continuity and reliability of the needle dispensing process. At the same time, the width of the needle passage in this device can be quickly adjusted to match different needle specifications; the needle-blocking plate mechanism achieves precise control of the material flow rate. In addition, the control unit can program the operating rhythm of each dispensing unit uniformly or independently, thereby achieving a comprehensive improvement in dispensing accuracy and production efficiency.

[0016] Other features and advantages of the present invention will be disclosed in detail in the following detailed description and accompanying drawings. Attached Figure Description

[0017] Figure 1 is a schematic diagram of the overall structure of the present invention; Figure 2 is a schematic diagram of one side of the needle wheel mechanism and the needle roller mechanism of the present invention on the fixed frame; Figure 3 is a schematic diagram of the other side of the needle wheel mechanism and the needle roller mechanism of the present invention on the fixed frame; Figure 4 is a schematic diagram of the inner structure of the fixed frame of the present invention; Figure 5 is an enlarged schematic diagram of part A in Figure 4; Figure 6 is a schematic diagram of the structure of the material collection unit of the present invention on the frame; Figure 7 is a schematic diagram of the position of the front needle plate and the rear needle plate of the present invention on the pressure plate.

[0018] The figures are labeled as follows: 1. Frame; 2. Material distribution unit; 201. Fixed frame; 202. Feeding mechanism; 202-1. Material box; 202-1(1) Needle collection chamber; 202-1(2) Needle dispensing chamber; 202-2. Material box seat; 202-3. Front needle guide plate; 202-4. Rear needle guide plate; 202-5. Needle passage; 203. Needle blocking plate mechanism; 203-1. Support frame; 203-2. Needle blocking plate; 203-3. Through port; 203-4. Adjusting handle; 204. Needle dispensing wheel mechanism; 204-1. Needle dispensing shaft; 204-2. Needle dispensing part; 20 4-3, First rotary motor; 204-4, First motor base; 204-5, First synchronous pulley; 204-6, First synchronous belt; 205, Needle roller mechanism; 205-1, Needle roller shaft; 205-2, Needle roller disc; 205-3, Second rotary motor; 205-4, Second motor base; 205-5, Second synchronous pulley; 205-6, Second synchronous belt; 3, Material collection unit; 301, Upper material collection hopper; 302, Lower material collection hopper; 303, Needle outlet; 4, Control unit; 401, Control panel; 402, Display panel; 5, Pressure plate; 6, Spring groove; 7, Spring. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] As shown in Figure 1, in an embodiment of the present invention, a needle distribution mechanism includes a frame 1, several material dispensing units 2, a material collecting unit 3, and a control unit 4. The several material dispensing units 2 are all located on the upper part of the material collecting unit 3, and the material dispensing units 2 are connected to the material collecting unit 3. The several material dispensing units 2, the material collecting unit 3, and the control unit 4 are all installed on the frame 1.

[0021] Specifically, several material distribution units 2 are installed side-by-side on the upper part of the frame 1. The number of these material distribution units 2 can be determined according to the types of needles required for actual production. For example, if the product requires five different specifications of needles, five independent material distribution units 2 can be set accordingly. Each material distribution unit 2 is detachably connected to the frame 1, such as by bolt fastening, which facilitates the maintenance or replacement of individual material distribution units 2. All material distribution units 2 are located above the same material collection unit 3 in the vertical direction.

[0022] The inlet at the upper end of the collecting unit 3 corresponds to and is connected to the lower outlet of each of the distributing units 2 above, so as to receive the needles sent out in an orderly manner from each distributing unit 2.

[0023] The control unit 4 is fixedly installed on one side of the frame 1, in a position convenient for the operator to observe and operate. The control unit 4 is electrically connected to the drive components in each material dispensing unit 2 via internal wiring. By operating the control unit 4, the operator can set and monitor the operating status of the entire needle dispensing mechanism.

[0024] As shown in Figures 2-5, in this embodiment, the material distribution unit 2 includes a fixed frame 201, a feeding mechanism 202, a needle-stopping plate mechanism 203, a needle-shifting wheel mechanism 204, and a needle roller mechanism 205; the fixed frame 201 is detachably mounted from the frame 1; the feeding mechanism 202, the needle-shifting wheel mechanism 204, and the needle roller mechanism 205 are installed sequentially from top to bottom within the fixed frame 201; the needle-stopping plate mechanism 203 operates within the feeding mechanism 202, and the needle-stopping plate mechanism 203 is connected to both the feeding mechanism 202 and the fixed frame 201.

[0025] Specifically, the material distribution unit 2 includes a sturdy fixed frame 201, which is usually assembled from bent metal sheets or aluminum profiles. The whole unit is rigidly connected to the aforementioned frame 1 by fasteners such as bolts, which ensures stability during operation and makes it easy to disassemble from the frame 1 for maintenance or as a spare unit.

[0026] Inside the fixed frame 201, a feeding mechanism 202 is installed at the top, forming the initial storage and preparation channel for the needles. Immediately below the feeding mechanism 202, a needle-shifting wheel mechanism 204 is installed. Below the needle-shifting wheel mechanism 204, a needle roller mechanism 205 is installed. This top-middle-bottom arrangement allows the needles to flow sequentially from storage and sorting to individual separation, relying on gravity and the coordinated action of the aforementioned mechanisms.

[0027] In addition, the needle stop plate mechanism 203 is used to precisely adjust the flow rate and opening / closing of the needle supplied from the upper part to the lower part of the feeding mechanism 202.

[0028] As shown in Figure 6, in this embodiment, the material collection unit 3 includes an upper material collection hopper 301, a lower material collection hopper 302, and a needle outlet 303. The upper material collection hopper 301 is detachably connected to the frame 1. The upper material collection hopper 301, the lower material collection hopper 302, and the needle outlet 303 are connected sequentially from top to bottom, and the upper material collection hopper 301 and the lower material collection hopper 302 are detachably connected. The lower material collection hopper 302 and the needle outlet 303 are an integral structure.

[0029] Specifically, the collecting unit 3 is a guide structure with a gradually narrowing diameter from top to bottom. Its uppermost end is an upper collecting hopper 301, which is typically shaped like an inverted frustum or a flared mouth. The opening at its top must be designed to completely cover and receive the outlet needles of all the distributing units 2 above it. The upper collecting hopper 301 is detachably fixed to the frame 1 via connecting lugs or flanges on its outer wall using bolts or other fasteners. This provides great flexibility for the installation and maintenance of the collecting unit 3.

[0030] Below the upper hopper 301, the lower hopper 302 is connected. The bottom outlet of the upper hopper 301 and the top inlet of the lower hopper 302 are detachably and sealed together by means of clamps, threads, or quick couplings. This facilitates separation of the two hoppers for cleaning any possible needle blockages or for internal inspection.

[0031] The lower end of the lower hopper 302 tapers and extends to form a needle outlet 303. In this structure, the lower hopper 302 and the needle outlet 303 are not two separately manufactured and reassembled parts, but are manufactured as a continuous, seamless integral structure through a one-piece molding process. This ensures a smooth and continuous flow path for the needle from the lower hopper 302 to the final needle outlet 303, avoiding the risk of needle jamming due to misalignment or dirt accumulation at the interface.

[0032] The entire process of the collection unit 3 is as follows: needles from different distribution units 2 first fall into the spacious space of the upper collection hopper 301 for initial collection, and then enter the lower collection hopper 302 through its contracted bottom under the action of gravity. The conical wall of the lower collection hopper 302 further sorts and guides the needle flow, and finally all needles are neatly discharged through the integrated barrel-shaped needle outlet 303, thus completing the mixed proportion output of needles of various specifications.

[0033] In this embodiment, the feeding mechanism 202 includes a material box 202-1, a material box seat 202-2, a front needle guide plate 202-3 with an arc-shaped groove on its upper part, a rear needle guide plate 202-4, and a needle guide channel 202-5; the material box 202-1 is located on the upper part of the material box seat 202-2, and the material box 202-1 communicates with the material box seat 202-2; both the material box 202-1 and the material box seat 202-2 are detachably mounted to the fixed frame 201; the front needle guide plate 202-3 and the rear needle guide plate 202-4 are both located inside the material box seat 202-2, and the front needle guide plate 202-3 and the rear needle guide plate 202-4 are located inside the material box seat 202-2. A needle passage 202-5 is formed between them. The front needle plate 202-3 and the rear needle plate 202-4 are adjustable to the material box seat 202-2. The material box 202-1 includes a needle collection chamber 202-1 (1) and a needle dispensing chamber 202-1 (2). The needle dispensing chamber 202-1 (2) is located between the needle collection chamber 202-1 (1) and the material box seat 202-2. The bottom of the needle collection chamber 202-1 (1) and the bottom of the needle dispensing chamber 202-1 (2) are both inclined towards the material box seat 202-2. The needle collection chamber 202-1 (1) and the needle dispensing chamber 202-1 (2) are an integral structure.

[0034] Specifically, the material box 202-1 is located directly above the material box base 202-2, and the two are connected at the joint, allowing the needles inside the material box 202-1 to fall smoothly into the material box base 202-2. For ease of installation, cleaning, or replacement, both the material box 202-1 and the material box base 202-2 are detachably connected to the fixing frame 201 of the dispensing unit 2 independently through connections such as clips, screws, or guide rails.

[0035] The material box holder 202-2 is a shell structure with an internal cavity. Inside this cavity, a front needle guide plate 202-3 and a rear needle guide plate 202-4 are arranged side-by-side. The top of the front needle guide plate 202-3 has a downward-recessed arc-shaped groove. The front needle guide plates 202-3 and 202-4 are placed parallel to each other within the material box holder 202-2, and the gap between them forms the path for the needle to pass downwards, i.e., the needle passage 202-5, which has an S-shaped cross-section. It is worth noting that the installation of both the front needle guide plates 202-3 and 202-4 within the material box holder 202-2 is adjustable, allowing the operator to change the distance between them as needed, thereby adjusting the width of the needle passage 202-5 to accommodate needles of different thicknesses or specifications.

[0036] The material box 202-1 includes a large needle collection compartment 202-1 (1) for storing needles to be distributed in batches; and a narrower needle distribution compartment 202-1 (2) located directly below the needle collection compartment 202-1 (1). The needle distribution compartment 202-1 (2) serves as a transition channel between the needle collection compartment 202-1 (1) and the material box seat 202-2 below. The bottom planes of both the needle collection compartment 202-1 (1) and the needle distribution compartment 202-1 (2) are designed as inclined surfaces sloping towards the material box seat 202-2 below them. The entire material box 202-1, including the needle collection compartment 202-1 (1) and the needle distribution compartment 202-1 (2), is a single component manufactured by injection molding or integral molding of metal sheet, ensuring structural strength and avoiding needle jamming problems that may be caused by internal connection gaps.

[0037] Therefore, the flow path of the needles in the feeding mechanism 202 is as follows: the needles are added in batches to the needle collection chamber 202-1 (1), slide into the needle dispensing chamber 202-1 (2) along the inclined bottom, and then prepare to enter the needle passage 202-5 formed by the front needle plate 202-3 and the rear needle plate 202-4 in the material box seat 202-2, which has an adjustable width, in preparation for subsequent precise sorting and single-piece separation.

[0038] In this embodiment, the needle-blocking plate mechanism 203 is located directly above the needle-dispensing chamber 202-1 (2) and the material box seat 202-2; the needle-blocking plate mechanism 203 includes a support frame 203-1, a needle-blocking plate 203-2, a through-hole 203-3, and an adjusting handle 203-4 with a screw at the lower end; the support frame 203-1 is located at the upper end outside the material collection chamber, and the support frame 203-1 is detachably set from the fixed frame 201; the needle-blocking plate 203-2 is located inside the material collection chamber, and the needle-blocking plate 203-2 Located at the lower end of the support frame 203-1, the needle stop plate 203-2 is slidably connected to the collection bin; the support frame 203-1 has a through-hole 203-3 in the middle, and the adjusting handle 203-4 is threadedly engaged with the needle stop plate 203-2 through the through-hole 203-3, and the adjusting handle 203-4 is rotatedly engaged with the support frame 203-1; by adjusting the handle 203-4 and the needle stop plate 203-2, the channel between the collection bin and the needle dispensing bin 202-1 (2) has two states: open and closed.

[0039] Specifically, the needle-blocking plate mechanism 203 is located directly above the area where the needle-dispensing chamber 202-1 (2) and the material box seat 202-2 are connected within the feeding mechanism 202. It can manually adjust the rate at which needles are released from the needle-collecting chamber 202-1 (1) to the needle-dispensing chamber 202-1 (2), or even completely block the flow path.

[0040] The needle-blocking plate mechanism 203 includes a support frame 203-1, which is typically door-shaped or bridge-shaped. The support frame 203-1 spans across the material box 202-1 of the feeding mechanism 202, specifically located at the upper outer edge of the needle collection chamber 202-1 (1) of the material box 202-1. The two ends of the support frame 203-1 are detachably connected to the fixing frame 201 of the dispensing unit 2 by screws or clips, thereby achieving stable installation.

[0041] Extending downwards from the middle of the support frame 203-1 into the needle collection chamber 202-1(1) is a needle-stopping plate 203-2. The shape of this needle-stopping plate 203-2 matches the cross-section of the connecting opening 203-3 between the needle collection chamber 202-1(1) and the needle dispensing chamber 202-1(2). The needle-stopping plate 203-2 and the side wall of the needle collection chamber 202-1(1) are connected by a sliding groove or guide rail structure to ensure that it can only rise and fall smoothly in the vertical direction without swaying.

[0042] A through-hole 203-3 is opened in the middle of the support frame 203-1. The adjusting handle 203-4 passes through the through-hole 203-3 from top to bottom. A screw is machined at the lower end of the adjusting handle 203-4, and the screw forms a threaded engagement with a threaded sleeve fixed in the body of the needle stop plate 203-2. At the same time, the rod of the adjusting handle 203-4 and the through-hole 203-3 on the support frame 203-1 are rotated through a bearing or a smooth bushing, so that the handle can rotate freely but its axial position is limited by the support frame 203-1.

[0043] When the operator rotates the adjusting handle 203-4 clockwise or counterclockwise, the screw and the needle-stopping plate 203-2 are driven to rise or fall vertically through the threaded transmission between them. When the needle-stopping plate 203-2 falls, its bottom edge gradually approaches or even completely covers the lower edge of the channel between the needle collecting chamber 202-1 (1) and the needle dispensing chamber 202-1 (2), thereby reducing or completely closing the needle flow channel. Conversely, when the needle-stopping plate 203-2 rises, the channel opens, and the needle falls from the needle collecting chamber 202-1 (1) into the needle dispensing chamber 202-1 (2) under the action of gravity. By rotating the adjusting handle 203-4, the opening of the channel can be controlled, thereby achieving fine adjustment of the needle flow rate. According to the above structure, the operator can conveniently set the initial flow rate according to the needle specifications and the required feeding rhythm before or during the operation of the device. At the same time, if the needle gets stuck in the channel between the needle collection chamber 202-1 (1) and the needle dispensing chamber 202-1 (2), the operator can raise the needle blocking plate 203-2 by rotating the adjustment handle 203-4 in the opposite direction, thereby expanding the channel space or disturbing the stuck needle, helping it to get out of the blockage and fall smoothly. This is an important prerequisite for ensuring that the subsequent material dispensing steps proceed in an orderly manner.

[0044] In this embodiment, the needle-shifting wheel mechanism 204 includes a needle-shifting shaft 204-1, a needle-shifting part 204-2, a first rotary motor 204-3, a first motor base 204-4, two first synchronous pulleys 204-5, and a first synchronous belt 204-6; the needle-shifting shaft 204-1 is located in the arc-shaped groove on the upper part of the front needle plate 202-3, and one end of the needle-shifting shaft 204-1 is rotatably connected to the inside of the fixed frame 201, while the other end of the needle-shifting shaft 204-1 passes through the fixed frame 201 and is located outside the fixed frame 201; the needle-shifting shaft 204-1 A fixed needle-pulling part 204-2 is located on the upper part of the front needle plate 202-3; the first rotary motor 204-3 is installed inside the fixed frame 201 through the first motor base 204-4, and the rotating end of the first rotary motor 204-3 passes through the fixed frame 201 and is located outside the fixed frame 201; one end of the needle-pulling shaft 204-1 located outside the fixed frame 201 and the rotating end of the first rotary motor 204-3 are both fixed with the first synchronous pulley 204-5; the first synchronous belt 204-6 is sleeved on the two first synchronous pulleys 204-5.

[0045] Specifically, the needle-shifting shaft 204-1 is horizontally positioned, with its shaft body positioned precisely within the arc-shaped groove on the upper surface of the front needle plate 202-3 inside the material box seat 202-2. One end of the needle-shifting shaft 204-1 is rotatably connected to the internal structure of the fixed frame 201 of the material distribution unit 2 via a bearing, thus obtaining stable rotational support; the other end extends through a pre-drilled hole on the side wall of the fixed frame 201 to the external space of the fixed frame 201.

[0046] The needle-shifting part 204-2 is fixedly installed on the section of the needle-shifting shaft 204-1 located above the front needle plate 202-3, that is, inside the material box seat 202-2. The needle-shifting part 204-2 typically consists of multiple radially protruding fingers, which periodically move the needle body as the shaft rotates.

[0047] The first rotary motor 204-3 is securely mounted inside the fixed frame 201 via a dedicated first motor mount 204-4. The rotary output shaft of the first rotary motor 204-3 also passes through the side wall of the fixed frame 201 and extends to the outside of the fixed frame 201.

[0048] Two first synchronous pulleys 204-5 are arranged outside the fixed frame 201. One first synchronous pulley 204-5 is fixedly mounted on the end of the needle-shifting shaft 204-1 that extends out of the frame, and the other first synchronous pulley 204-5 is fixedly mounted on the rotating end of the first rotary motor 204-3 that extends out of the frame. A closed-loop first synchronous belt 204-6 is fitted around the two first synchronous pulleys 204-5, thereby synchronously transmitting the rotational power of the first rotary motor 204-3 to the needle-shifting shaft 204-1.

[0049] At this point, when the control unit 4 starts the first rotary motor 204-3, the rotation of the first rotary motor 204-3, through the synchronous transmission formed by the first synchronous pulley 204-5 and the first synchronous belt 204-6, drives the needle-feeding shaft 204-1 to rotate at the same rhythm. The needle-feeding part 204-2, fixed on the needle-feeding shaft 204-1, rotates accordingly, and the finger or groove on it will rhythmically guide the needles that slide down from the arc-shaped groove of the front needle plate 202-3 into the entrance of the needle passage 202-5 formed by the front needle plate 202-3 and the rear needle plate 202-4, realizing the conversion from free fall to controlled propulsion.

[0050] In this embodiment, the needle roller mechanism 205 includes a needle roller shaft 205-1, a needle roller disc 205-2, a second rotary motor 205-3, a second motor base 205-4, two second synchronous pulleys 205-5, and a second synchronous belt 205-6. The needle roller shaft 205-1 is located at the lower part of the needle passage 202-5, and one end of the needle roller shaft 205-1 is rotatably connected to the inside of the fixed frame 201, while the other end of the needle roller shaft 205-1 passes through the fixed frame 201 and is located outside the fixed frame 201. The lower part of the needle channel 202-5 is fixed with a needle roller disc 205-2; the second rotary motor 205-3 is installed inside the fixed frame 201 through the second motor base 205-4, and the rotation point of the second rotary motor 205-3 passes through the fixed frame 201 and is located outside the fixed frame 201; one end of the needle roller shaft 205-1 located outside the fixed frame 201 and the rotation end of the second rotary motor 205-3 are both fixed with the second synchronous pulley 205-5; the second synchronous belt 205-6 is sleeved on the two second synchronous pulleys 205-5.

[0051] Specifically, the shaft of the needle roller 205-1 is horizontally positioned below the outlet of the needle channel 202-5. One end of the needle roller 205-1 is rotatably connected to the internal structure of the fixed frame 201 of the material distribution unit 2 through a bearing, thereby obtaining stable rotational support; the other end extends through a reserved hole on the side wall of the fixed frame 201 to the external space of the fixed frame 201.

[0052] A needle roller disc 205-2 is fixedly installed on the section of the needle roller shaft 205-1 located below the needle passage 202-5, that is, below the material box seat 202-2. The needle roller disc 205-2 is a disc-shaped component with several regularly shaped notches evenly machined on its outer periphery. The size and depth of each notch are just enough to securely accommodate a single needle. As the needle roller disc 205-2 rotates intermittently or continuously, these notches pass sequentially below the exit of the needle passage 202-5, receiving and carrying away a single needle.

[0053] The drive unit is powered by a second rotary motor 205-3. This motor is securely mounted inside the fixed frame 201 via a dedicated second motor mount 205-4. The motor's rotary output shaft also extends through the side wall of the fixed frame 201 to the external space for power transmission.

[0054] Two second synchronous pulleys 205-5 are arranged outside the fixed frame 201. One of the second synchronous pulleys 205-5 is fixedly mounted on the end of the needle roller shaft 205-1 that extends out of the frame, and the other is fixedly mounted on the rotating end of the second rotary motor 205-3 that extends out of the frame. A ring-shaped second synchronous belt 205-6 is fitted around the two second synchronous pulleys 205-5, thereby accurately and synchronously transmitting the rotational power of the second rotary motor 205-3 to the needle roller shaft 205-1.

[0055] When the control unit 4 controls the second rotary motor 205-3 to run, the rotation of the second rotary motor 205-3 is transmitted through the second synchronous pulley 205-5 and the second synchronous belt 205-6, driving the needle roller shaft 205-1 and the needle roller disc 205-2 fixed thereon to rotate synchronously. The notches on the outer edge of the needle roller disc 205-2 are aligned with and pass through the lower outlet of the needle passage 202-5 in sequence, and the needles that fall in an orderly manner from the needle passage 202-5 are entered into the notches one by one. Then, driven by the continued rotation of the needle roller disc 205-2, the needles are smoothly transported to the predetermined position and released, so that they fall into the collection unit 3 below in a controlled single form, thereby completing the operation from continuous feeding to single-sequential feeding.

[0056] In this embodiment, the control unit 4 is electrically connected to the first rotary motor 204-3 and the second rotary motor 205-3. The control unit 4 includes a control panel 401 and a display panel 402, both of which are detachably mounted to the frame 1.

[0057] The control unit 4 contains a control circuit board, a power module, and electrical interfaces. Through internally laid cables, the control unit 4 establishes an electrical connection with the first rotary motor 204-3 and the second rotary motor 205-3 in each material distribution unit 2, thereby enabling it to send control commands to these motors, such as start, stop, speed adjustment, and direction control, and to receive feedback signals from the first rotary motor 204-3 and the second rotary motor 205-3, such as encoder signals.

[0058] The operator-facing portion of control unit 4 integrates a human-machine interface, primarily consisting of a control panel 401 and a display panel 402. The control panel 401 is equipped with various input devices, such as physical buttons, knobs, touch areas, or emergency stop switches, allowing the operator to input operating parameters, select operating modes, or perform manual intervention. The display panel 402 is typically an LCD screen or a digital tube array, used to display the mechanism's operating status in real time, such as current operating speed, number of needles supplied, motor status, or fault alarm information.

[0059] The entire control unit 4 is detachably and fixedly installed to the frame 1 via mechanical connectors. This facilitates the overall maintenance, upgrading, or replacement of the control unit 4.

[0060] By setting parameters through the control panel 401, the operator can uniformly or independently control the operating rhythm and coordination of the first rotary motor 204-3 and the second rotary motor 205-3 in each material distribution unit 2. All settings and operating statuses are clearly displayed on the display panel 402.

[0061] As shown in Figure 7, in this embodiment, pressure plates 5 are provided at both ends of the bottom of the front needle plate 202-3 and the rear needle plate 202-4. The pressure plates 5 are detachably connected to the material box seat 202-2. Spring grooves 6 are provided at both ends of the upper part of the rear needle plate 202-4. Springs 7 are provided in the spring grooves 6. The front needle plate 202-3 and the rear needle plate 202-4 are movably connected to the material box seat 202-2 through the springs 7.

[0062] Specifically, inside the material box seat 202-2, at the bottom of the front needle plate 202-3 and the rear needle plate 202-4, that is, at the two ends of the bottom surface of the inner cavity of the material box seat 202-2, a long strip of pressure plate 5 is installed.

[0063] The pressure plate 5 is detachably connected to the base of the material box seat 202-2 by fasteners such as screws. The bottom edges of the front needle guide plate 202-3 and the rear needle guide plate 202-4 are restricted within the narrow guide groove or gap formed between the pressure plate 5 and the material box seat 202-2, so that the front needle guide plate 202-3 and the rear needle guide plate 202-4 can be adjusted in position along the length direction of the pressure plate 5, that is, perpendicular to the needle passage 202-5, thereby realizing the adjustment of the distance between the needle guide plate and the pressure plate 5.

[0064] Specifically, a spring groove 6 is machined at each of the upper ends of the rear needle plate 202-4 facing the side wall of the material box seat 202-2. A cylindrical helical spring 7 is placed in each spring groove 6. One end of the spring 7 abuts against the bottom of the spring groove 6, and the other end abuts against the corresponding boss or mounting surface on the side wall of the material box seat 202-2.

[0065] The rear needle plate 202-4 and the material box seat 202-2 are connected by spring 7. When a needle of slightly larger size or irregular shape occasionally passes through the narrow channel formed by the two needle plates, the pressure exerted by the needle on the inner side of the needle plate can compress spring 7. The front needle plate 202-3 and the rear needle plate 202-4 have a floating space of 0.5mm under pressure, ensuring the smooth progress of the needle passing process.

[0066] The present invention also provides an operating method for a needle dispensing machine as described in any of the preceding claims, comprising the following steps: S1: adjusting the relative position between the front needle-passing plate 202-3 and the rear needle-passing plate 202-4 in the dispensing unit 2 according to the specification of the needle to be dispensed, so as to form a needle-passing channel 202-5 that matches the needle specification; adjusting the needle-blocking plate mechanism 203 to control the flow rate of needles entering the material box seat 202-2 from the needle collection chamber 202-1 (1); S2: placing the needles into the needle collection chamber 202-1 (1) of the feeding mechanism 202; setting the operating speed of the first rotary motor 204-3 and the second rotary motor 205-3 by the control unit 4. S3: Start the equipment. Control unit 4 controls the first rotary motor 204-3 to drive the needle-pulling part 204-2 to rotate, rhythmically pushing the needles from the material box seat 202-2 and through the needle passage 202-5, buffering and sorting the falling needles; Control unit 4 controls the second rotary motor 205-3 to drive the needle roller 205-2 to rotate. The needle roller 205-2 receives the needles falling from the needle passage 202-5 and rhythmically feeds them into the collection unit 3 below in single-piece form; S4: The needles of different specifications output from each material distribution unit 2 are collected in the collection unit 3 and finally discharged uniformly from the needle outlet 303.

[0067] Experimental Example: To verify the technical effectiveness of this needle dispensing mechanism, the inventors conducted practical application tests. The tests aimed to quantitatively evaluate its dispensing accuracy, operating efficiency, anti-jamming reliability, and long-term stability when processing needles of various sizes.

[0068] The test used a prototype machine equipped with five independent dispensing units. The test subjects were five different diameter metal needles: size 1 (0.4mm), size 2 (0.6mm), size 3 (0.8mm), size 4 (1.0mm), and size 5 (1.2mm). The test process and results are as follows: First, a multi-size mixing ratio accuracy test was conducted. The five sizes of needles were loaded into their respective dispensing units, and the target output ratio was set to 1:1:1:1:1 via the control unit. The mechanism ran continuously for a preset cycle, with a target output of 100 needles of each size, totaling 500 needles. After the cycle, all needles were collected from the needle outlet of the collection unit and sorted and counted. The results showed that the actual output quantities of the five sizes of needles were 99, 101, 100, 100, and 100 respectively, totaling 500 needles. The actual mixing ratio is highly consistent with the preset 1:1:1:1:1, with a maximum quantity deviation within ±1 needle and a mixing accuracy error of less than 1%. This result confirms that the present invention can achieve high-precision, synchronized arbitrary ratio mixing of five or more needle specifications.

[0069] Secondly, a comparative test was conducted on processing efficiency and jamming issues. A third-size needle (0.8mm in diameter) was selected as a representative, and the needle feeding mechanism of this invention (experimental group) and the traditional vibratory feeder sorting mechanism (control group) were tested for continuous feeding capacity for one hour. Recorded data showed that the experimental group output 18,300 needles, with an average efficiency of 305 needles / minute, and only one minor jamming event occurred during the entire test, which could be immediately resolved by fine-tuning the adjustment handle. The control group output 11,800 needles, with an average efficiency of 197 needles / minute, and experienced 18 jamming events requiring manual intervention. The comparison shows that the mechanism of this invention improves feeding efficiency by approximately 55% while reducing the jamming failure rate by approximately 94%, significantly improving production smoothness and efficiency.

[0070] Subsequently, an adaptive capability test of the needle passage was conducted on the key structure. This test aimed to verify the effectiveness of the micro-floating design of the front and rear needle plates under spring action in preventing hard jamming and protecting the needles. Taking the third specification (0.8mm) needle as an example, the needle passage width of the corresponding feeding unit was fixed at 0.82mm. Needles with diameters between 0.78mm and 0.82mm (within tolerance) and a small number of needles with a diameter of approximately 0.84mm (slightly larger than the nominal passage width) were successively input. The test found that all needles within the tolerance range passed smoothly without any jamming. For the slightly wider 0.84mm needles, more than 96% of the needles could still pass smoothly. All passing needles were inspected under a magnifying glass, and no scratches or bends were found on the surface caused by forced passage. This result proves that the micro-floating space provided by the spring effectively absorbs the needle tolerance and adjustment margin, achieving "flexible" needle passage, which greatly avoids the risk of needle jamming and product damage while ensuring the channel guidance accuracy.

[0071] Finally, a long-term operational stability test was conducted. The prototype was run continuously at full load for 8 hours with five different needle sizes in a 1:1:1:1:1 ratio. Throughout the test, the mechanism operated smoothly, the temperature rise of each motor was normal, and no serious malfunctions leading to shutdown occurred. After the test, the total output needle quantity and the ratio of each needle size deviated from the theoretical values ​​by less than 1.5%, indicating that the multi-size ratio accuracy and operational stability were reliably maintained during long-term continuous operation.

[0072] In summary, the present invention provides a needle fitting mechanism and its operating method, which can flexibly adapt to needles of different specifications, achieve stable and orderly single needle separation and delivery, and efficiently integrate and converge multiple needle flows with high reliability.

[0073] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0074] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A needle-dispensing mechanism, characterized in that, The needle distribution mechanism includes a frame (1), several material distribution units (2), a material collection unit (3) and a control unit (4). Several of the material distribution units (2) are located on the upper part of the material collection unit (3), and the material distribution units (2) are connected to the material collection unit (3). Several of the material distribution units (2), the material collection unit (3) and the control unit (4) are all installed on the frame (1).

2. The needle-feeding mechanism according to claim 1, characterized in that, The material distribution unit (2) includes a fixed frame (201), a feeding mechanism (202), a needle-stopping plate mechanism (203), a needle-shifting wheel mechanism (204), and a needle roller mechanism (205); the fixed frame (201) is detachably mounted from the frame (1); the feeding mechanism (202), the needle-shifting wheel mechanism (204), and the needle roller mechanism (205) are installed sequentially from top to bottom within the fixed frame (201); the needle-stopping plate mechanism (203) operates within the feeding mechanism (202), and the needle-stopping plate mechanism (203) is connected to both the feeding mechanism (202) and the fixed frame (201).

3. The needle-dispensing mechanism according to claim 1, characterized in that, The material collection unit (3) includes an upper material collection hopper (301), a lower material collection hopper (302), and a needle outlet (303). The upper material collection hopper (301) is detachably connected to the frame (1). The upper material collection hopper (301), the lower material collection hopper (302), and the needle outlet (303) are connected sequentially from top to bottom. The upper material collection hopper (301) and the lower material collection hopper (302) are detachably connected. The lower material collection hopper (302) and the needle outlet (303) are an integral structure.

4. The needle-feeding mechanism according to claim 2, characterized in that, The feeding mechanism (202) includes a material box (202-1), a material box seat (202-2), a front needle guide plate (202-3) with an arc-shaped groove on the upper part, a rear needle guide plate (202-4), and a needle guide channel (202-5); the material box (202-1) is located on the upper part of the material box seat (202-2), and the material box (202-1) is connected to the material box seat (202-2); both the material box (202-1) and the material box seat (202-2) are detachably mounted to the fixed frame (201); the front needle guide plate (202-3) and the rear needle guide plate (202-4) are both located inside the material box seat (202-2), and the front needle guide plate (202-3) and the rear needle guide plate (202-4) are connected to each other. A needle passage (202-5) is formed between the needles. The front needle plate (202-3) and the rear needle plate (202-4) are adjustable to the material box seat (202-2). The material box (202-1) includes a needle collection chamber (202-1(1)) and a needle dispensing chamber (202-1(2)). The needle dispensing chamber (202-1(2)) is located between the needle collection chamber (202-1(1)) and the material box seat (202-2). The bottom of the needle collection chamber (202-1(1)) and the bottom of the needle dispensing chamber (202-1(2)) are both inclined towards the material box seat (202-2). The needle collection chamber (202-1(1)) and the needle dispensing chamber (202-1(2)) are an integral structure.

5. The needle-dispensing mechanism according to claim 4, characterized in that, The needle-blocking plate mechanism (203) is located directly above the needle-dispensing chamber (202-1 (2)) and the material box seat (202-2); the needle-blocking plate mechanism (203) includes a support frame (203-1), a needle-blocking plate (203-2), a through-hole (203-3), and an adjusting handle (203-4) with a screw at the lower end; the support frame (203-1) is located at the upper end outside the material collection chamber, and the support frame (203-1) is detachably set from the fixed frame (201); the needle-blocking plate (203-2) is located inside the material collection chamber, and the needle-blocking plate (203-2) is positioned... At the lower end of the support frame (203-1), the needle stop plate (203-2) is slidably connected to the collection bin; the support frame (203-1) has a through-hole (203-3) in the middle, and the adjusting handle (203-4) is threadedly engaged with the needle stop plate (203-2) through the through-hole (203-3), and the adjusting handle (203-4) is rotatably engaged with the support frame (203-1); through the adjusting handle (203-4) and the needle stop plate (203-2), the channel between the collection bin and the needle dispensing bin (202-1 (2)) has two states: open and closed.

6. The needle-dispensing mechanism according to claim 5, characterized in that, The needle-shifting wheel mechanism (204) includes a needle-shifting shaft (204-1), a needle-shifting part (204-2), a first rotary motor (204-3), a first motor base (204-4), two first synchronous pulleys (204-5), and a first synchronous belt (204-6). The needle-shifting shaft (204-1) is located in the arc-shaped groove on the upper part of the front needle plate (202-3), and one end of the needle-shifting shaft (204-1) is rotatably connected to the inside of the fixed frame (201), while the other end of the needle-shifting shaft (204-1) passes through the fixed frame (201) and is located outside the fixed frame (201). The needle-shifting shaft (204-1) is located at the front... The upper part of the needle plate (202-3) is fixed with a needle-pulling part (204-2); the first rotary motor (204-3) is installed inside the fixed frame (201) through the first motor base (204-4), and the rotating end of the first rotary motor (204-3) passes through the fixed frame (201) and is located outside the fixed frame (201); the first synchronous pulley (204-5) is fixed at one end of the needle-pulling shaft (204-1) located outside the fixed frame (201) and the rotating end of the first rotary motor (204-3); the first synchronous belt (204-6) is sleeved on the two first synchronous pulleys (204-5).

7. The needle-feeding mechanism according to claim 6, characterized in that, The needle roller mechanism (205) includes a needle roller shaft (205-1), a needle roller disc (205-2), a second rotary motor (205-3), a second motor base (205-4), two second synchronous pulleys (205-5), and a second synchronous belt (205-6). The needle roller shaft (205-1) is located at the lower part of the needle passage (202-5), and one end of the needle roller shaft (205-1) is rotatably connected to the inside of the fixed frame (201), while the other end of the needle roller shaft (205-1) passes through the fixed frame (201) and is located outside the fixed frame (201). The lower part of the track (202-5) is fixed with a needle roller disc (205-2); the second rotary motor (205-3) is installed inside the fixed frame (201) through the second motor base (205-4), and the rotation point of the second rotary motor (205-3) passes through the fixed frame (201) and is located outside the fixed frame (201); one end of the needle roller shaft (205-1) located outside the fixed frame (201) and the rotation end of the second rotary motor (205-3) are both fixed with a second synchronous pulley (205-5); the second synchronous belt (205-6) is sleeved on the two second synchronous pulleys (205-5).

8. The needle-dispensing mechanism according to claim 7, characterized in that, The control unit (4) is electrically connected to the first rotary motor (204-3) and the second rotary motor (205-3). The control unit (4) includes a control panel (401) and a display panel (402). The control panel (401) and the display panel (402) are detachably mounted to the frame (1).

9. The needle-feeding mechanism according to claim 7, characterized in that, The bottom ends of the front needle plate (202-3) and the rear needle plate (202-4) are provided with pressure plates (5). The pressure plates (5) are detachably connected to the material box seat (202-2). The upper ends of the rear needle plate (202-4) are provided with spring grooves (6). Springs (7) are provided in the spring grooves (6). The front needle plate (202-3) and the rear needle plate (202-4) are movably connected to the material box seat (202-2) through the springs (7).

10. A method for operating a needle-feeding machine as described in any one of claims 1-9, characterized in that, The steps include: S1: According to the specifications of the needles to be distributed, adjust the relative positions between the front needle plate (202-3) and the rear needle plate (202-4) in the feeding unit (2) to form a needle passage (202-5) that matches the needle specifications; adjust the needle blocking plate mechanism (203) to control the flow rate of needles entering the material box seat (202-2) from the needle collection chamber (202-1 (1)); S2: Place the needles into the needle collection chamber (202-1 (1)) of the feeding mechanism (202); set the operating parameters including the rotation speed of the first rotary motor (204-3) and the second rotary motor (205-3) through the control unit (4); S3: Start the equipment and control Unit (4) controls the first rotary motor (204-3) to drive the needle-pulling part (204-2) to rotate, and rhythmically pulls the needle from the material box seat (202-2) and through the needle passage (202-5) to buffer and comb the falling needle; control unit (4) controls the second rotary motor (205-3) to drive the needle roller (205-2) to rotate, and the needle roller (205-2) receives the needle falling from the needle passage (202-5) and rhythmically feeds it into the collection unit (3) below in the form of single needles; S4: the needles of different specifications output by each material distribution unit (2) are gathered in the collection unit (3) and finally discharged uniformly from the needle outlet (303).

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