High-speed edge cutting device for tufted carpet production

Abstract

The invention discloses a high-speed edge cutting device for tufted carpet production, which comprises a rack, at least two sets of edge cutting assemblies arranged in the carpet conveying direction, and a guide rail and a moving assembly for driving the edge cutting assemblies to move back and forth, and the edge cutting assemblies are oppositely cut through a disc blade; in the edge cutting process, the edge cutting resistance is monitored in real time through the pressure detection device, when it is detected that the edge cutting resistance is abnormal, the edge cutting assembly is controlled to automatically exit, the follow-up edge cutting assembly continues to work, and non-stop switching is achieved; meanwhile, a single driving machine is adopted to form reverse shearing by the two disc blades through a combined transmission mode of a transmission belt and a gear set, and clamping stagnation in a high-speed running state is avoided by combining elastic protection of a synchronous belt and gear transmission resistance detection; the tufted carpet subjected to edge cutting sequentially enters the procedures of conveying, guiding, rolling and packaging, and continuity and operation safety of the production process are guaranteed.

Description

Technical Field

[0001] This invention relates to the field of carpet production equipment, specifically a high-speed edge-cutting device for producing tufted carpets. Background Technology

[0002] With the increasing demand for carpet products in modern homes, public spaces, and commercial venues, tufted carpets are widely used in the industrial production of various carpet products due to their high production efficiency, strong pattern adaptability, and controllable costs. On continuous production lines for tufted carpets, after completing processes such as tufting and backing curing, the carpet blanks typically require edge trimming on both sides to obtain a regular finished width and remove excess material. This trimming process is usually completed while the carpet is being continuously conveyed, placing high demands on the stability and reliability of the trimming equipment.

[0003] In existing technologies, edge-cutting devices for tufted carpets mostly employ a single-set disc cutter or a single-sided cutting structure. During high-speed operation, the edge-cutting blades are easily affected by factors such as changes in carpet thickness, uneven tuft density, and pile accumulation, resulting in significant fluctuations in cutting resistance. This can lead to problems such as napping, uneven cuts, and even blade jamming. When the edge-cutting assembly becomes dull or jammed, it usually requires machine shutdown for manual cleaning or blade replacement, which not only affects production continuity but also reduces the overall operating efficiency of the production line.

[0004] Furthermore, in existing edge-cutting equipment, the judgment of the edge-cutting state largely relies on manual experience or fixed operating time, lacking real-time detection methods based on actual changes in edge-cutting resistance. This makes it difficult to identify abnormal edge-cutting states in a timely and accurate manner, easily leading to continuous operation of the equipment under abnormal conditions, increasing the risk of damage to the cutting tools, transmission structure, and the entire machine. At the same time, some equipment designs do not adequately consider the safe switching of edge-cutting components under abnormal conditions. Improper control during the switching process can easily cause interference or collisions between edge-cutting components, posing certain safety hazards.

[0005] In view of the above problems, a high-speed edge cutting device for tufted carpet production is proposed. Summary of the Invention

[0006] The purpose of this invention is to provide a high-speed edge-cutting device for tufted carpet production, so as to solve the problems mentioned in the background art.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a high-speed edge-cutting device for tufted carpet production, comprising a frame, wherein the frame is provided with a bottom transverse guide rail and a top transverse guide rail for guiding the edge-cutting component to move back and forth along the carpet conveying direction; the bottom transverse guide rail and the top transverse guide rail are arranged vertically correspondingly, and a moving component is installed on the bottom transverse guide rail and the top transverse guide rail, wherein a mounting support is provided on the moving component, and the edge-cutting component is fixedly installed on the mounting support; at least two sets of edge-cutting components are arranged back and forth along the carpet conveying direction, wherein the front edge-cutting component is in the edge-cutting position, and the rear edge-cutting component is in the standby position; a pressure detection device is provided at the connection position between the frame and the front edge-cutting component for detecting the force state of the edge-cutting component during the edge-cutting process, and when the detected force signal exceeds a preset threshold, the moving component is driven to move the front edge-cutting component out of the edge-cutting position, and the rear edge-cutting component is driven to move forward along the bottom transverse guide rail and the top transverse guide rail to the edge-cutting position.

[0008] Preferably, the cutting assembly includes a fixing base, the fixing base is fitted with a housing, the front end of the fixing base is fitted with a fixing bracket, the rear side of the fixing bracket is fitted with a drive motor, and the output end of the drive motor drives the opposing disc blades to rotate.

[0009] Preferably, a second cutter shaft is mounted at the bottom of the fixed bracket, the drive motor is mounted on the back of the fixed bracket, and a first cutter shaft is mounted at the output end of the drive motor. A synchronous transmission wheel is rotatably mounted in the middle of the fixed bracket, a synchronous pulley is mounted in the middle of the first cutter shaft, a synchronous belt is mounted on the outside of the synchronous pulley and the synchronous transmission wheel, and a meshing gear set is mounted at the end of the synchronous transmission wheel and the end of the second cutter shaft.

[0010] Preferably, the outer surfaces of the outer flanges of the first and second cutter shafts are welded with protruding rods, and the outer surface of the disc blade is provided with limiting holes of corresponding size and position to the protruding rods.

[0011] Preferably, the limiting hole is sleeved on the outer surface of the protruding rod, and the outer sides of the first and second cutter shafts are provided with external threads, and a round nut is screwed onto the outer surface of the external threads.

[0012] Preferably, the outer side of the disc blade has a single-sided cutting edge, and the non-cutting edge planes of the two disc blades are in contact with each other.

[0013] Preferably, the pressure detection device collects the real-time force value F of the cutting component during the cutting process, and judges based on the difference ΔF = F - F0 between the force value F and the preset benchmark force value F0. When ΔF is continuously greater than the threshold F within a preset time interval... tWhen the cutting resistance of the cutting component increases abnormally, the switching control of the cutting component is triggered.

[0014] Preferably, an entry-position sensor and an exit-position sensor are provided at the corresponding travel ends of the bottom and top transverse guide rails. The entry-position sensor and the exit-position sensor are used to output position signals of the cutting assembly entering the cutting position and exiting the cutting position, respectively. The control system performs interlock control on the drive of the front and rear cutting assemblies based on the position signals. When the exit-position signal of the front cutting assembly is not received, the rear cutting assembly is prohibited from moving to the cutting position to avoid mutual interference or collision between the two sets of cutting assemblies.

[0015] Preferably, the rotational speed of the disc blade is matched and controlled according to the conveying speed of the tufted carpet body, and the rotational speed of the disc blade is limited to a preset safe rotational speed range; the first cutter shaft and the second cutter shaft are driven by a synchronous belt, and the synchronous belt is set with a maximum allowable tension. When the transmission resistance between the disc blades exceeds the maximum allowable tension due to foreign objects being clamped or abnormal cutting resistance, the synchronous belt elastically slips or jumps out to release the rigid transmission between the first cutter shaft and the second cutter shaft, thereby preventing the disc blade from jamming or structural damage at high rotational speed.

[0016] Preferably, a driven rotary pressure transmitter is provided between the back of the transmission bracket and the transmission assembly. The pressure transmitter is used to detect the change in rotational resistance between the first cutter shaft and the second cutter shaft during synchronous transmission. When a sudden increase in rotational resistance is detected within a preset time, it is determined that a clamping or jamming state has occurred between the two disc blades. The control system performs speed limiting, deceleration or shutdown control on the drive motor and prohibits the cutting assembly from performing switching actions to avoid continuing to cut edges or malfunctioning under abnormal conditions.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: The high-speed edge-cutting device for tufted carpet production provided by the present invention, by setting at least two sets of movable edge-cutting components at the front and rear on the frame, and combining pressure detection and switching control logic, enables the tufted carpet to complete stable edge cutting without stopping during continuous conveying. When the edge-cutting component in the working position experiences lint jamming, dulling, or abnormally increased edge-cutting resistance, it can automatically exit the edge-cutting position and be taken over by the subsequent edge-cutting component, thereby ensuring the continuity of the edge-cutting process and the stability of the production cycle. At the same time, through the transmission structure of the synchronous belt and gear set, the two disc blades form a counter-shearing state, and the elastic characteristics of the synchronous belt are utilized. Under abnormal operating conditions, mechanical overload protection is achieved to prevent the disc blade from jamming or structural damage under high-speed operation. By installing pressure detection devices on the stress path of the frame and gear transmission parts, the cutting resistance and blade clamping status are monitored in real time. In abnormal conditions, orderly switching control and warning reminders are provided to significantly improve the safety of equipment operation and maintenance efficiency. In addition, after the tufted carpet is cut, it goes through the conveying, guiding, rolling and packaging processes in sequence to achieve continuous connection between cutting, rolling and packaging. The overall structure is compact and the operation logic is clear, which solves the problems of easy stop, jamming, unsafe switching and poor production continuity in the high-speed cutting of tufted carpets in the existing technology. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the overall assembly of the present invention; Figure 3 This is a side view of the structure of the present invention; Figure 4 This is a schematic diagram of the assembly structure of the edge-cutting station in this invention; Figure 5 This is a schematic diagram of the overall structure of the disc cutting edge assembly in this invention; Figure 6 This is a schematic diagram of the internal structure of the disc cutting edge assembly in this invention; Figure 7 This is an exploded structural diagram of the disc cutting edge assembly in this invention; Figure 8 This is an exploded structural diagram of the disc cutting edge assembly in this invention from another perspective.

[0019] In the diagram: 1. Frame; 11. Column; 12. Bottom transverse guide rail; 13. Top transverse guide rail; 14. Moving component; 15. Mounting support; 2. Edge trimming component; 21. Fixed base; 22. Protective cover; 23. Fixed bracket; 24. Drive motor; 25. First cutter shaft; 26. Second cutter shaft; 27. Synchronous transmission wheel; 28. Gear set; 29. ​​Disc blade; 210. Protruding rod; 211. Limiting hole; 3. Transition conveying mechanism; 4. Guide support frame; 5. Rolling mechanism; 6. Packaging drive mechanism; 71. Tufted carpet body; 72. Edge trimming material. Detailed Implementation

[0020] 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.

[0021] Please see Figure 1-8 This invention provides a technical solution: a high-speed edge-cutting device for tufted carpet production, comprising a frame 1, on which a bottom transverse guide rail 12 and a top transverse guide rail 13 are provided for guiding the edge-cutting assembly 2 to move back and forth along the carpet conveying direction; the bottom transverse guide rail 12 and the top transverse guide rail 13 are arranged vertically correspondingly, and a moving assembly 14 is installed on the bottom transverse guide rail 12 and the top transverse guide rail 13, and a mounting support 15 is provided on the moving assembly 14, and the edge-cutting assembly 2 is fixedly installed on the mounting support 15; at least two sets of edge-cutting assemblies 2 are arranged back and forth along the carpet conveying direction, wherein the front edge-cutting assembly 2 is in the edge-cutting position, and the rear edge-cutting assembly 2 is in the standby position; A pressure detection device is provided at the connection position between the frame 1 and the front edge cutting assembly 2 to detect the force state of the edge cutting assembly 2 during the edge cutting process. When the detected force signal exceeds the preset threshold, the drive moving assembly 14 drives the front edge cutting assembly 2 to exit the edge cutting position and drives the rear edge cutting assembly 2 to move forward along the bottom horizontal guide rail 12 and the top horizontal guide rail 13 to the edge cutting position.

[0022] In practical applications, the frame 1 serves as the load-bearing foundation of the entire machine. It is preferably constructed using welded steel profiles or assembled profiles to ensure sufficient overall rigidity and vibration resistance under high-speed edge-cutting conditions. The frame 1 has a bottom transverse guide rail 12 and a top transverse guide rail 13, respectively. These rails are arranged vertically and vertically along the conveying direction of the tufted carpet. They can have the same structural form, preferably linear guide rails, secondary guide rails, or wear-resistant slide rails, used to synchronously guide and constrain the forward and backward linear movement of the edge-cutting assembly 2, thereby preventing the edge-cutting assembly 2 from swaying or tilting during movement.

[0023] Movable components 14 are mounted on the bottom transverse guide rail 12 and the top transverse guide rail 13. The movable components 14 can be in the form of sliders, slide blocks, roller assemblies, or linear modules, forming a stable sliding or rolling contact with the guide rails to reduce motion resistance and improve movement accuracy. A mounting support 15 is provided on the movable components 14, which is vertically positioned to provide a stable mounting interface for the edge-cutting component 2. This ensures that the edge-cutting component 2 maintains a fixed spatial posture at the edge-cutting position, thereby guaranteeing a stable and reliable edge-cutting position relationship between the disc blade 29 and the edge of the tufted carpet.

[0024] The trimming assembly 2 is fixedly installed on the mounting support 15, and at least two sets are arranged front and rear along the conveying direction of the tufted carpet. In practical applications, it is preferred to set two sets of trimming assemblies 2, one in the front and one in the rear. The front trimming assembly 2 is in the trimming position and undertakes the current trimming operation, while the rear trimming assembly 2 is in the standby position and is used to continue trimming if the front trimming assembly 2 experiences tufting, dulling, or abnormally increased trimming resistance. This front-rear arrangement allows the trimming operation to be switched without stopping the machine, avoiding the impact on overall production efficiency due to machine downtime for cleaning or tool replacement.

[0025] A pressure detection device is installed at the connection point between the frame 1 and the front trimming assembly 2. This device is preferably a pressure sensor, pressure transmitter, or an equivalent force detection element, used to collect real-time data on the force state of the trimming assembly 2 during the trimming process. During actual control, the control system determines the change in trimming resistance of the trimming assembly 2 based on the collected force signals. When the trimming resistance exceeds a preset threshold and persists for a certain period, the system determines that the trimming state of the front trimming assembly 2 is abnormal. At this time, the control system drives the moving assembly 14 to move the front trimming assembly 2 out of the trimming position along the bottom transverse guide rail 12 and the top transverse guide rail 13, and simultaneously drives the rear trimming assembly 2 forward to the trimming position, thereby completing the automatic switching between the trimming assemblies 2 and enabling continuous trimming of the tufted carpet.

[0026] During the switching process described above, the movement of the front cutting edge assembly 2 and the rear cutting edge assembly 2 is sequentially controlled by the control system. By interlocking and restricting the movement state of the moving assembly 14, when one cutting edge assembly 2 is in a moving state, the other cutting edge assembly 2 remains stationary, so as to avoid mutual interference or collision between the two sets of cutting edge assemblies 2 during the forward and backward movement, thereby improving the safety and reliability of the equipment operation.

[0027] Specifically, the edge-cutting assembly 2 includes a fixed base 21, an outer shell 22 is fitted on the outside of the fixed base 21, a fixed bracket 23 is fitted on the front end of the fixed base 21, and a drive motor 24 is fitted on the rear side of the fixed bracket 23. The output end of the drive motor 24 drives the opposing disc blades 29 to rotate.

[0028] In practical applications, the trimming assembly 2 includes a fixed base 21, which serves as the basic load-bearing structure of the trimming assembly 2. The fixed base 21 is preferably a machined or welded integral metal structure to ensure sufficient structural strength and rigidity under high-speed rotation and continuous stress conditions. The fixed base 21 supports the various transmission components and cutter shaft components inside the trimming assembly 2 and is integrally fixed to the moving assembly 14 via the mounting support 15, allowing the trimming assembly 2 to move back and forth along the guide rail direction with the moving assembly 14.

[0029] The fixed base 21 is externally fitted with a housing 22, which protects the rotating parts and transmission structure of the cutting assembly 2. In practical applications, the housing 22 can be made of sheet metal or engineering plastic molding, and its structure is preferably detachable to facilitate daily maintenance, cleaning of lint, and replacement of the cutting blades. The housing 22 effectively prevents a large amount of lint generated during the cutting process of the tufted carpet from entering the transmission area, thereby reducing the probability of wear and malfunction of the transmission components.

[0030] A fixed bracket 23 is mounted on the front end of the fixed base 21. The fixed bracket 23 is arranged along the conveying direction of the tufted carpet body 71 and serves as the main mounting structure for the cutter shaft and transmission components. The fixed bracket 23 preferably adopts a plate or frame structure and forms a rigid connection with the fixed base 21 to ensure the relative positional stability of the first cutter shaft 25 and the second cutter shaft 26 under high-speed rotation, thereby ensuring that the opposing shearing relationship between the disc blades 29 does not shift.

[0031] A drive motor 24 is mounted on the rear side of the fixed bracket 23. The drive motor 24 provides rotational power to the edge-cutting assembly 2, and its output shaft is connected to the first cutter shaft 25. In practical applications, the drive motor 24 is preferably a motor with adjustable speed, such as a servo motor or a frequency converter motor, so as to match and adjust the rotational speed of the disc blades 29 according to the conveying speed, thickness, and material differences of the tufted carpet body 71. By directly driving the first cutter shaft 25 to rotate through the drive motor 24, the disc blades 29 set on the first cutter shaft 25 and the second cutter shaft 26 form a stable opposing rotational state, thereby realizing continuous edge-cutting operation on the edge of the tufted carpet body 71.

[0032] Under the above structural arrangement, the drive motor 24, the fixed bracket 23, the first cutter shaft 25 and the second cutter shaft 26 together constitute the core cutting execution mechanism of the cutting assembly 2. Its power transmission path is clear and its structure is compact. It can maintain cutting accuracy and operational stability under long-term continuous operation, and meet the actual needs of high-speed cutting and reliable operation in the production process of tufted carpet.

[0033] Specifically, a second cutter shaft 26 is mounted at the bottom of the fixed bracket 23, a drive motor 24 is mounted on the back of the fixed bracket 23, and a first cutter shaft 25 is mounted at the output end of the drive motor 24. A synchronous transmission wheel 27 is rotatably mounted in the middle of the fixed bracket 23, a synchronous pulley is mounted in the middle of the first cutter shaft 25, a synchronous belt is mounted on the outside of the synchronous pulley and the synchronous transmission wheel 27, and a gear set 28 that meshes with each other is mounted at the end of the synchronous transmission wheel 27 and the end of the second cutter shaft 26.

[0034] In practical applications, a second cutter shaft 26 is mounted at the bottom of the fixed bracket 23. The second cutter shaft 26 is arranged parallel to the first cutter shaft 25 and is rotatably mounted on the fixed bracket 23 via a bearing assembly, thereby enabling the second cutter shaft 26 to achieve stable rotation with low frictional resistance. As a driven cutter shaft, the structural strength and axial rigidity of the second cutter shaft 26 are designed based on the radial and axial forces borne by the disc blade 29 under high-speed cutting conditions to avoid bending or wobbling during long-term operation.

[0035] The drive motor 24 is mounted on the back of the fixed bracket 23, and its output end is equipped with a first cutter shaft 25. The first cutter shaft 25 acts as the active cutter shaft and rotates under the direct drive of the drive motor 24. A synchronous pulley is mounted in the middle of the first cutter shaft 25, and a synchronous transmission wheel 27 is rotatably mounted in the middle of the fixed bracket 23. The synchronous transmission wheel 27 is mounted on the fixed bracket 23 through a bearing structure to ensure its rotational stability during synchronous transmission. A synchronous belt is mounted on the outside of both the synchronous pulley and the synchronous transmission wheel 27, thereby forming a flexible synchronous transmission relationship between the first cutter shaft 25 and the synchronous transmission wheel 27.

[0036] At the end of the synchronous drive wheel 27 and the end of the second cutter shaft 26, respectively, meshing gear sets 28 are fitted. The gear sets 28 are preferably spur gears or helical gears, used to transmit the rotational motion of the synchronous drive wheel 27 to the second cutter shaft 26, and to ensure that the second cutter shaft 26 and the first cutter shaft 25 rotate synchronously in opposite directions. Through the combined transmission of the synchronous belt and gear sets 28, the first cutter shaft 25 and the second cutter shaft 26 can achieve stable and reliable reverse rotation while maintaining speed matching, thereby ensuring that the two disc blades 29 form a continuous and symmetrical shearing action within the cutting area.

[0037] In actual operation, the synchronous belt enables a certain degree of flexible transmission between the first cutter shaft 25 and the synchronous transmission wheel 27. This flexible transmission can buffer when the cutting resistance fluctuates, reducing the direct impact of the impact load on the drive motor 24 and the gear set 28. The gear set 28 ensures the synchronization and phase relationship between the rotation speed of the second cutter shaft 26 and the first cutter shaft 25, so that the two disc blades 29 can maintain a stable relative position relationship even at high speed, avoiding a decrease in cutting quality due to transmission lag or asynchrony.

[0038] Through the transmission structure combining the synchronous belt and gear set 28, the edge cutting assembly 2 can maintain a stable edge cutting state even when facing complex working conditions such as changes in the thickness of the tufted carpet body 71, uneven edge density, or sudden increases in local resistance. This provides a reliable mechanical basis for subsequent control of the rotation speed of the disc blade 29, anti-jamming protection, and abnormal state detection.

[0039] Specifically, the outer surfaces of the outer flanges of the first cutter shaft 25 and the second cutter shaft 26 are welded with protruding rods 210, and the outer surface of the disc blade 29 is provided with limiting holes 211 of corresponding size and position to the protruding rods 210.

[0040] In this embodiment, the outer surfaces of the outer flanges of the first cutter shaft 25 and the second cutter shaft 26 are provided with protruding rods 210. The protruding rods 210 are preferably fixed along the circumferential direction, and their number can be one or more, the specific number being determined based on the diameter of the disc blade 29 and the force applied to the cutting edge. The protruding rods 210 serve as circumferential limiting structures, used to circumferentially position the disc blade 29 after installation, thereby preventing the disc blade 29 from rotating or misaligning relative to the cutter shaft under high-speed rotation and repeated stress conditions.

[0041] Correspondingly, a limiting hole 211 is formed on the outer surface of the disc blade 29. The position and size of the limiting hole 211 correspond to the protrusion 210, so that when the disc blade 29 is assembled to the first cutter shaft 25 or the second cutter shaft 26, the limiting hole 211 can be accurately fitted onto the outside of the protrusion 210. Through the cooperation between the limiting hole 211 and the protrusion 210, the disc blade 29 is mechanically constrained in the circumferential direction, structurally eliminating the risk of relative rotation of the blade caused by fluctuations in cutting edge resistance or transmission impact.

[0042] In the actual assembly process, the disc blade 29 is first circumferentially positioned with the protruding rod 210 through the limiting hole 211, and then installed through the axial fixing structure. This assembly method constrains the disc blade 29 in the radial, axial, and circumferential directions, making it particularly suitable for environments with periodic impact loads and uneven cutting resistance during high-speed edge cutting of tufted carpets. Through this structural design, even if the synchronous belt experiences elastic slippage or the gear set 28 is subjected to instantaneous impact, the disc blade 29 can still maintain a stable relative position, without rotational misalignment or displacement, thus ensuring the stability of the cutting position and the consistency of the cutting quality.

[0043] In addition, the mating structure of the protruding rod 210 and the limiting hole 211 provides a clear positioning reference for the disassembly and replacement of the disc blade 29. When performing blade maintenance, replacement or reinstallation, it can effectively avoid installation deviations caused by manual assembly errors, improve assembly efficiency and reduce the risk of misassembly, and meet the actual needs of industrial production for maintenance convenience and operational reliability.

[0044] Specifically, the limiting hole 211 is sleeved on the outer surface of the protrusion 210, and the outer sides of the first cutter shaft 25 and the second cutter shaft 26 are provided with external threads, and a round nut is screwed onto the outer surface of the external threads.

[0045] In this embodiment, both the first cutter shaft 25 and the second cutter shaft 26 are provided with external thread structures on their outer sides. The external threads are arranged along the axial direction of the cutter shaft and are used to cooperate with the round nut to axially fix the disc blade 29. After the disc blade 29 completes the circumferential positioning of the protrusion 210 and the limiting hole 211, its inner hole is sleeved on the outer side of the first cutter shaft 25 or the second cutter shaft 26 and fits against the mounting base surface at the end of the cutter shaft, thereby forming a stable axial assembly relationship.

[0046] A round nut is screwed onto the external thread on the outside of the first cutter shaft 25 or the second cutter shaft 26. During tightening, the round nut is pushed inward axially, applying axial clamping force to the disc blade 29, so that the disc blade 29 is reliably pressed between the cutter shaft end face and the round nut. Through this axial clamping structure, the disc blade 29 does not experience axial movement or loosening during high-speed rotation and repeated cutting force, thereby ensuring the stability of the cutting edge position and the consistency of the cutting edge width.

[0047] In practical applications, the tightening force of the round nut can be set according to the diameter and thickness of the disc blade 29 and the cutting conditions to ensure reliable fixing while avoiding blade deformation due to excessive tightening. An anti-loosening structure, such as an anti-loosening washer, a backstop structure, or a thread locking method, can be provided between the external thread and the round nut to prevent the round nut from loosening under long-term high-speed operation and vibration conditions, thereby improving the overall reliability of the cutting assembly 2.

[0048] The axial fixing method, achieved through the engagement of an external thread and a round nut, combined with the circumferential limiting structure formed by the protruding rod 210 and the limiting hole 211, constrains the disc blade 29 in the radial, axial, and circumferential directions, forming a stable three-way positioning and installation structure. This structure is particularly suitable for working environments with abundant lint and large resistance fluctuations during high-speed edge cutting of tufted carpets. It effectively reduces the risk of blade loosening, misalignment, or abnormal wear, while facilitating quick disassembly and replacement of the disc blade 29 during maintenance, meeting the dual requirements of operational stability and maintenance efficiency in industrial production.

[0049] Specifically, the outer side of the disc blade 29 has a single-sided cutting edge, and the non-cutting edge planes of the two disc blades 29 are in contact with each other.

[0050] In this embodiment, the power for the edge-cutting assembly 2 is provided by a single drive motor 24. The drive motor 24 serves as the power source for the edge-cutting assembly 2, and its output end is connected to the first cutter shaft 25. The rotational power output by the drive motor 24 is first transmitted to the synchronous drive wheel 27 via a transmission belt, causing the synchronous drive wheel 27 to rotate synchronously under the drive of the transmission belt. The synchronous drive wheel 27, as an intermediate transmission component, further transmits its rotational motion to the second cutter shaft 26 via a gear set 28 located at its end. This causes the second cutter shaft 26 to rotate in the opposite direction to the first cutter shaft 25 under the action of the gear set 28.

[0051] Through the aforementioned transmission method, the drive unit 24 only needs to output power in a single direction of rotation to achieve synchronous counter-rotation of the first cutter shaft 25 and the second cutter shaft 26 via the combined transmission structure of the transmission belt and gear set 28. This causes the two disc blades 29, respectively mounted on the first cutter shaft 25 and the second cutter shaft 26, to form a counter-shearing edge-cutting state. This transmission structure has a clear power path and a compact structure, which helps to reduce the number of drive components. By combining the flexibility of the transmission belt with the synchronous transmission characteristics of the gear set 28, it ensures that the rotational speeds of the two disc blades 29 are matched while achieving stable and reliable counter-shearing motion, meeting the actual application requirements of high-speed continuous edge cutting for tufted carpets.

[0052] The outer edge of the disc blade 29 is configured with a single-sided cutting edge structure, with the cutting edge continuously formed along the circumference of the disc blade 29, while the other side surface of the disc blade 29 is a non-cutting edge plane. When the two disc blades 29 are installed, their non-cutting edge planes are fitted together, forming a stable fit between the two disc blades 29, and forming an opposing shearing structure during rotation.

[0053] During the actual edge cutting process, the first cutter shaft 25 and the second cutter shaft 26 drive the two disc blades 29 to rotate synchronously in opposite directions, and the edge of the tufted carpet body 71 passes between the two disc blades 29. Since the cutting edges of the two disc blades 29 are respectively set towards the edge of the carpet, in the state of counter-rotation, the cutting force on the edge of the carpet is in a shearing state rather than a tearing state, thus achieving a flat and continuous edge cutting effect under high-speed operation.

[0054] Compared to single-blade or serrated cutting methods, the counter-cutting structure significantly reduces pilling, curling, or fiber dragging during the edge cutting process of tufted carpets, making it particularly suitable for carpets with high tuft density, long fibers, or soft materials. In actual production, even if the edge thickness of the tufted carpet body 71 fluctuates, this counter-cutting method can still maintain a neat and consistent cut edge, improving the edge quality of the finished carpet.

[0055] Furthermore, the non-cutting surfaces of the two disc blades 29 are fitted together, ensuring a stable blade gap within the cutting area. This facilitates control over the cutting width and position, preventing dimensional deviations due to variations in blade spacing. This structural design allows the cutting assembly 2 to maintain both cutting efficiency and quality, as well as operational stability, under high-speed continuous operation, thus meeting the practical requirements for cutting precision and reliability in the industrial production of tufted carpets.

[0056] Specifically, the pressure detection device collects the real-time force value F of the cutting component 2 during the cutting process, and judges based on the difference ΔF = F - F0 between the force value F and the preset benchmark force value F0. When ΔF is continuously greater than the threshold F within the preset time interval, the device detects the force. t When the cutting resistance of the cutting component 2 is abnormally increased, the switching control of the cutting component 2 is triggered.

[0057] A pressure detection device is installed at the connection point between the frame 1 and the front trimming assembly 2. The pressure detection device is used to detect the stress state of the trimming assembly 2 in real time during the trimming process. The pressure detection device is preferably a pressure sensor or a pressure transmitter, and its installation position is located on the force transmission path of the trimming assembly 2. This ensures that the trimming resistance generated by the disc blade 29 acting on the tufted carpet body 71 during the trimming process can be accurately reflected in the pressure detection device, thereby improving the accuracy and reliability of the detection data.

[0058] During actual operation, the control system continuously collects the force signal output by the pressure detection device and sets a reference force value F0 based on the initial operating state or calibration condition of the equipment. The control system compares the real-time collected current force value F with the reference force value F0, and calculates the force difference ΔF = F - F0 to reflect the change in cutting resistance. When the cutting assembly 2 is in normal cutting state, the force difference ΔF remains within the preset normal fluctuation range; when the disc blade 29 experiences burr jamming, dulling, fiber accumulation in the cutting area, or foreign matter intrusion, the cutting resistance increases accordingly, and the force difference ΔF shows a continuous upward trend.

[0059] The control system further performs a time-based judgment on the force difference ΔF. If the force difference ΔF continues to be greater than the threshold F within a preset time interval, the system will detect the force difference. t When the current edge-cutting component 2 is in an abnormal edge-cutting state, it is determined that the current edge-cutting component 2 is in an abnormal edge-cutting state. By introducing a time-based judgment condition, misjudgments caused by local thickness changes at the carpet edge, instantaneous uneven fiber density, or brief resistance fluctuations can be effectively avoided, thereby improving the stability and accuracy of the switching trigger judgment.

[0060] Through the aforementioned pressure detection and threshold judgment methods, the working status of the edge cutting component 2 can be evaluated in real time based on the actual edge cutting resistance. The control system no longer relies solely on fixed running time or human experience for switching judgments, but automatically identifies abnormal edge cutting states based on force changes under real working conditions, providing a reliable judgment basis for the subsequent automatic switching of the edge cutting component 2, and ensuring the continuity and stability of the tufted carpet edge cutting process.

[0061] Specifically, an entry-position sensor and an exit-position sensor are installed at the corresponding travel ends of the bottom horizontal guide rail 12 and the top horizontal guide rail 13. The entry-position sensor and the exit-position sensor are used to output the position signals of the cutting component 2 entering the cutting position and exiting the cutting position, respectively. The control system performs interlock control on the drive of the front cutting component 2 and the rear cutting component 2 based on the position signals. When the exit-position signal of the front cutting component 2 is not received, the rear cutting component 2 is prohibited from moving to the cutting position to avoid mutual interference or collision between the two cutting components 2.

[0062] In this embodiment, when the control system confirms that the front cutting edge assembly 2 is in an abnormal cutting edge state based on the force judgment result of the pressure detection device, it enters the cutting edge assembly switching execution process. The switching execution process is sequentially controlled by the control system, the purpose of which is to ensure the continuity of cutting edge while avoiding mutual interference or collision between the two sets of cutting edge assemblies 2 during movement.

[0063] Before the switching begins, the control system first decelerates or stops the drive motor 24 of the front edge-cutting assembly 2, causing the disc blade 29 to gradually exit the edge-cutting state, thereby reducing the safety risks caused by the high-speed rotation of the blade during the switching process. After confirming that the drive motor 24 of the front edge-cutting assembly 2 is at a stop or a safe speed, the control system drives the moving assembly 14 to move the front edge-cutting assembly 2 outward along the bottom transverse guide rail 12 and the top transverse guide rail 13, exiting the edge-cutting position.

[0064] During the process of the front trimming assembly 2 retracting from the trimming position, the control system monitors its movement status in real time and determines whether the front trimming assembly 2 has completely left the trimming area based on the preset exit stroke or arrival signal. Only after confirming that the front trimming assembly 2 has completely retracted from the trimming position will the control system allow the rear trimming assembly 2 to perform a forward movement, thus forming a clear sequential control relationship and avoiding the situation where the two trimming assemblies 2 move simultaneously or in opposite directions within the guide rail stroke.

[0065] After the front trimming assembly 2 has exited and entered the maintenance position, the control system drives the rear trimming assembly 2 to move forward along the bottom transverse guide rail 12 and the top transverse guide rail 13, and stops moving after reaching the trimming position, so that the rear trimming assembly 2 enters the working state and continues to complete the trimming operation on the tufted carpet body 71. Through the above-mentioned sequential control method, the trimming assembly 2 can be smoothly switched in abnormal conditions, avoiding the impact on trimming quality or equipment operation safety due to improper switching process.

[0066] Furthermore, during the switching process, the control system sets interlocking conditions for the movement of the two sets of edge-cutting components 2, ensuring that when one edge-cutting component 2 is in a moving state, the other edge-cutting component 2 remains stationary. Simultaneously, if it detects that an edge-cutting component 2 is not fully withdrawn, not in position, or its drive has not stopped, the other edge-cutting component 2 is prohibited from executing movement commands. This interlocking control logic effectively avoids the risk of malfunction or collision of the edge-cutting components 2 during the switching process from both the control and execution levels, improving the operational safety and reliability of the entire edge-cutting device under continuous production conditions.

[0067] Specifically, the rotational speed of the disc blade 29 is matched and controlled according to the conveying speed of the tufted carpet body 71, and the rotational speed of the disc blade 29 is limited to a preset safe rotational speed range; the first cutter shaft 25 and the second cutter shaft 26 are driven by a synchronous belt, which is set with a maximum allowable tension. When the transmission resistance between the disc blades 29 exceeds the maximum allowable tension due to foreign objects being clamped or abnormal cutting resistance, the synchronous belt will elastically slip or jump out to release the rigid transmission between the first cutter shaft 25 and the second cutter shaft 26, so as to avoid the disc blades 29 from jamming or structural damage at high speed.

[0068] In this embodiment, the disc blade 29 continuously shears the edge of the tufted carpet body 71 at high speed during the edge-cutting operation. Its rotational speed is matched and controlled by the control system according to the carpet's conveying speed, ensuring a coordinated relationship between the cutting linear speed and the carpet's conveying speed. This avoids incomplete edge cutting due to excessively low speed, or excessive speed causing pilling, burning, or abnormal blade wear. To ensure the stability of the equipment during high-speed operation, the rotational speed of the disc blade 29 is limited to a preset safe speed range, which is set according to the carpet material, tuft density, and blade diameter.

[0069] A synchronous belt is used for transmission between the first cutter shaft 25 and the synchronous transmission pulley 27. The synchronous belt has a certain elasticity while transmitting power. Its initial tension is set according to the driving power and the cutting load, so that the synchronous belt can stably transmit torque under normal cutting conditions. When the cutting resistance between the disc blades 29 increases sharply due to tufting, foreign object clamping, or a sudden increase in local carpet thickness, the transmission load of the first cutter shaft 25 and the second cutter shaft 26 increases accordingly. At this time, the tension of the synchronous belt exceeds its maximum allowable tension.

[0070] When the tension on the synchronous belt exceeds the maximum allowable tension, the synchronous belt experiences elastic slippage or tooth skipping, thereby partially or completely disengaging the power transmission between the first cutter shaft 25 and the synchronous transmission pulley 27. This prevents the trimming assembly 2 from momentarily jamming or structurally damaging due to rigid transmission at high speeds. By utilizing the elastic slippage characteristics of the synchronous belt, the trimming assembly 2 can provide mechanical overload protection under abnormal stress conditions. This, combined with the aforementioned anomaly identification method based on pressure detection, improves the operational safety of the entire trimming device under complex working conditions.

[0071] After the synchronous belt slips or jumps off, the control system can determine that the trimming assembly 2 has entered an abnormal operating condition based on the change in the speed or transmission state of the drive motor 24, and then implement speed reduction or shutdown control on the speed of the disc blade 29 to prevent excessive driving force from being applied to the trimming assembly 2 after the synchronous belt protection action has occurred, thereby further reducing the risk of equipment damage. By combining the above-mentioned speed control with the elastic protection of the synchronous belt, the trimming assembly 2 can maintain efficient operation under high-speed trimming conditions and also has the self-protection capability to cope with sudden jamming conditions.

[0072] Specifically, a driven rotary pressure transmitter is installed between the back of the transmission bracket 23 and the transmission assembly. The pressure transmitter is used to detect the change in rotational resistance between the first cutter shaft 25 and the second cutter shaft 26 during synchronous transmission. When a sudden increase in rotational resistance is detected within a preset time, it is determined that a clamping or jamming state has occurred between the two disc blades 29. The control system performs speed limiting, deceleration or shutdown control on the drive motor 24 and prohibits the cutting assembly 2 from performing switching actions to avoid continuing to cut edges or malfunctioning under abnormal conditions.

[0073] In this embodiment, a driven rotary pressure transmitter is disposed between the back of the transmission bracket 23 and the gear set 28. The pressure transmitter forms an indirect contact or force coupling relationship with the gear set 28 to detect changes in the rotational resistance of the gear set 28 during transmission. The pressure transmitter does not directly participate in power output, but acts as a follow-up detection element, generating a corresponding pressure signal output in sync with the gear set 28's rotation or force changes during normal transmission.

[0074] During actual operation, when the first cutter shaft 25 and the second cutter shaft 26 are synchronously reverse-driven through the gear set 28, the meshing resistance borne by the gear set 28 mainly comes from the cutting resistance of the disc blade 29 on the edge of the tufted carpet body 71. Under normal cutting conditions, the meshing resistance of the gear set 28 remains within a relatively stable range, and the pressure signal output by the driven rotary pressure transmitter is thus within the normal fluctuation range.

[0075] When lint or foreign objects get caught between the two disc blades 29, or when the local resistance in the cutting area increases abnormally, the meshing resistance of the gear set 28 increases significantly within a short period of time, causing a sudden change in the force value sensed by the driven rotary pressure transmitter. Based on the changes in the collected pressure signal, the control system makes real-time judgments on the rotational resistance of the gear set 28. When a sudden increase in the pressure signal is detected within a preset time, it is determined that there is a risk of clamping or jamming between the two disc blades 29.

[0076] By installing a driven rotary pressure transmitter between the gear set 28 and the transmission support 23, the cutting assembly 2 can indirectly detect changes in the cutter shaft transmission resistance without altering the original transmission structure. This detection method complements the aforementioned pressure detection device based on the frame's force, enabling the identification of a continuous increase in overall cutting resistance and the rapid identification of momentary clamping or jamming between the disc blades 29, thereby improving the accuracy and response speed of abnormal operating condition identification.

[0077] Upon detecting an abnormally sudden increase in the transmission resistance of gear set 28, the control system implements speed limiting, deceleration, or shutdown control on drive motor 24, and prohibits the cutting assembly 2 from continuing to perform switching or high-speed cutting actions, in order to avoid damage to gear set 28, cutter shaft, or disc blade 29 caused by continued application of driving force under clamping conditions. Through the above structural design, the cutting device possesses multi-level anomaly detection and protection capabilities under high-speed cutting conditions, improving the operational safety and reliability of the entire equipment in continuous production environments.

[0078] In this embodiment, after the edges of the tufted carpet body 71 are trimmed by the edge-trimming assembly 2, it sequentially enters the transition conveying mechanism 3 and the guide support frame 4 along the conveying direction. The transition conveying mechanism 3 is located behind the edge-trimming assembly 2 and is used to receive the trimmed tufted carpet body 71, ensuring that the carpet maintains a continuous and stable conveying state after leaving the edge-trimming area. By setting up the transition conveying mechanism 3, the impact of speed changes or tension fluctuations on the overall posture of the carpet at the moment of edge trimming can be reduced, preventing the carpet edges from springing back, twisting, or locally stacking after trimming.

[0079] The guide support frame 4 is located behind the transition conveying mechanism 3. It guides and supports the tufted carpet body 71 that has been trimmed, keeping the carpet unfolded and flat before entering the subsequent rolling process. The support of the guide support frame 4 on the edges and body of the carpet prevents the carpet from sagging or deviating during the conveying process due to its own weight or high flexibility, which helps to improve the stability and rolling quality of the subsequent rolling process.

[0080] After the guide support is completed, the tufted carpet body 71 enters the winding mechanism 5. The winding mechanism 5 is used to continuously wind the tufted carpet with trimmed edges, forming a regular carpet roll. In practical applications, the winding mechanism 5 can be adjusted according to the width and thickness of the carpet to ensure uniform roll diameter and neat edges during the rolling process. After winding, the winding mechanism 5 transfers the rolled tufted carpet to the packaging drive mechanism 6 at the rear by lifting or displacement.

[0081] The packaging drive mechanism 6 is used to drive the rotation and packaging of the rolled tufted carpet. It can drive the entire carpet roll to rotate to cooperate with packaging processes such as bagging, stretching, or sealing. By separating the roll material mechanism 5 from the packaging drive mechanism 6, the roll material and packaging processes are made independent, which helps to improve the flexibility of production cycle and reduce the impact of a single station failure on the operation of the entire production line.

[0082] Furthermore, when the cutting assembly 2 is determined to be abnormal during the cutting process and a switching action is executed, the front cutting assembly 2 is moved to the outer maintenance position. To facilitate timely identification of abnormal conditions by on-site personnel, a warning system is installed in the corresponding area of ​​the maintenance position. The warning system may include an audible and visual alarm device, indicator lights, or information prompts. After the cutting assembly 2 has exited and entered the maintenance position, the control system sends a prompt signal to the warning system to remind the operator to clean, grind, or maintain the cutting assembly 2. Through the above-mentioned warning system, abnormal conditions can be visually identified, preventing the abnormal cutting assembly 2 from remaining in an unused state for a long time without being dealt with in a timely manner, thereby improving equipment maintenance efficiency and production continuity.

[0083] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-speed edge-cutting device for producing tufted carpets, characterized in that, The system includes a frame (1), on which a bottom transverse guide rail (12) and a top transverse guide rail (13) are provided for guiding the edge-cutting assembly (2) to move back and forth along the carpet conveying direction; the bottom transverse guide rail (12) and the top transverse guide rail (13) are arranged vertically and vertically respectively, and a moving assembly (14) is installed on the bottom transverse guide rail (12) and the top transverse guide rail (13), and a mounting support (15) is provided on the moving assembly (14), and the edge-cutting assembly (2) is fixedly installed on the mounting support (15); the edge-cutting assembly (2) is arranged in at least two sets along the carpet conveying direction, wherein the front edge-cutting assembly (2) is in the edge-cutting position and the rear edge-cutting assembly (2) is in the standby position; A pressure detection device is provided at the connection position between the frame (1) and the front edge cutting assembly (2) to detect the force state of the edge cutting assembly (2) during the edge cutting process. When the detected force signal exceeds the preset threshold, the moving assembly (14) is driven to drive the front edge cutting assembly (2) out of the edge cutting position, and the rear edge cutting assembly (2) is driven to move forward along the bottom horizontal guide rail (12) and the top horizontal guide rail (13) to the edge cutting position.

2. The high-speed edge-cutting device for tufted carpet production according to claim 1, characterized in that: The edge-cutting assembly (2) includes a fixed base (21), the fixed base (21) is fitted with a housing (22), the front end of the fixed base (21) is fitted with a fixed bracket (23), and the rear side of the fixed bracket (23) is fitted with a drive motor (24). The output end of the drive motor (24) drives the opposing disc blades (29) to rotate.

3. The high-speed edge-cutting device for tufted carpet production according to claim 2, characterized in that: The bottom end of the fixed bracket (23) is equipped with a second cutter shaft (26), the drive motor (24) is mounted on the back of the fixed bracket (23), and the output end of the drive motor (24) is equipped with a first cutter shaft (25). The middle part of the fixed bracket (23) is rotatably equipped with a synchronous transmission wheel (27), the middle part of the first cutter shaft (25) is equipped with a synchronous pulley, the synchronous pulley and the outside of the synchronous transmission wheel (27) are equipped with a synchronous belt, and the end of the synchronous transmission wheel (27) and the end of the second cutter shaft (26) are equipped with a gear set (28) that meshes with each other.

4. The high-speed edge-cutting device for tufted carpet production according to claim 3, characterized in that: The outer surfaces of the outer flanges of the first cutter shaft (25) and the second cutter shaft (26) are welded with protruding rods (210), and the outer surface of the disc blade (29) is provided with limiting holes (211) that correspond to the size and position of the protruding rods (210).

5. A high-speed edge-cutting device for tufted carpet production according to claim 4, characterized in that: The limiting hole (211) is sleeved on the outer surface of the protrusion (210), and the outer sides of the first cutter shaft (25) and the second cutter shaft (26) are provided with external threads, and a round nut is screwed onto the outer surface of the external threads.

6. The high-speed edge-cutting device for tufted carpet production according to claim 1, characterized in that: The outer side of the disc blade (29) is provided with a single-sided cutting edge, and the non-cutting edge planes of the two disc blades (29) are in contact with each other.

7. The high-speed edge-cutting device for tufted carpet production according to claim 1, characterized in that: The pressure detection device collects the real-time force value F of the cutting component (2) during the cutting process, and judges based on the difference ΔF = F - F0 between the force value F and the preset benchmark force value F0. When ΔF is continuously greater than the threshold F within the preset time interval, the device detects the force value. t When the edge cutting resistance of the edge cutting component (2) is abnormally increased, the switching control of the edge cutting component (2) is triggered.

8. The high-speed edge-cutting device for tufted carpet production according to claim 1, characterized in that: An entry-to-position sensor and an exit-to-position sensor are provided at the corresponding travel ends of the bottom horizontal guide rail (12) and the top horizontal guide rail (13). The entry-to-position sensor and the exit-to-position sensor are used to output the entry-to-position signal and exit-to-position signal of the cutting component (2) respectively. The control system performs interlock control on the drive of the front cutting component (2) and the rear cutting component (2) based on the position signal. When the exit-to-position signal of the front cutting component (2) is not received, the rear cutting component (2) is prohibited from moving to the cutting position.

9. A high-speed edge-cutting device for tufted carpet production according to claim 1, characterized in that: The rotational speed of the disc blade (29) is matched and controlled according to the conveying speed of the tufted carpet body (71), and the rotational speed of the disc blade (29) is limited to a preset safe rotational speed range; the first cutter shaft (25) and the second cutter shaft (26) are driven by a synchronous belt, and the synchronous belt is set with a maximum allowable tension. When the transmission resistance between the disc blades (29) exceeds the maximum allowable tension due to the clamping of foreign objects or abnormal cutting resistance, the synchronous belt will elastically slip or jump out to release the rigid transmission between the first cutter shaft (25) and the second cutter shaft (26).

10. A high-speed edge-cutting device for tufted carpet production according to claim 1, characterized in that: A driven rotary pressure transmitter is provided between the back of the transmission bracket (23) and the transmission assembly. The pressure transmitter is used to detect the change in rotational resistance between the first cutter shaft (25) and the second cutter shaft (26) during synchronous transmission. When a sudden increase in rotational resistance is detected within a preset time, it is determined that there is a clamping or jamming state between the two disc blades (29). The control system performs speed limiting, deceleration or shutdown control on the drive machine (24) and prohibits the cutting assembly (2) from performing switching actions.

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