Automatic fixed-length cutting and ball-forming method for fiber ball filter material

Abstract

The application belongs to the field of mechanical engineering, and particularly relates to a kind of automatic fixed-length shearing and ball-forming method of fiber ball filter material, aiming at solving the problems of traditional fiber ball filter material production relying on manual operation, low precision, low efficiency and unstable quality. The method includes five steps of tension control and straightening conveying, accurate length measurement and fixed-length shearing, automatic fiber segment collection and bundle arrangement, folding and ball-forming, finished product output and quality detection. Through the cooperation of laser displacement sensor and rotary encoder for length measurement, high-precision fixed-length segmentation is realized by cooperating with servo-driven disc shear cutter; automatic bundle arrangement of fiber segment is realized by negative pressure adsorption collection and bundle partition plate; folding mechanism and pneumatic binding device are used to realize ball-forming. The application integrates multiple processes into an automatic continuous production line, significantly improves the shearing precision, greatly improves the ball-forming efficiency, guarantees the product size consistency and quality stability, and eliminates the cost of manual transfer.

Description

Technical Field

[0001] This invention relates to the field of mechanical engineering technology, and in particular to an automated method for fixed-length shearing and ball forming of fiber ball filter media. Background Technology

[0002] Fiber ball filter media is a high-efficiency filter media widely used in deep sewage treatment, oilfield reinjection water filtration and air purification. It is made of fiber bundles that are cut to a fixed length and shaped into balls to form an elastic, highly porous spherical structure.

[0003] Currently, the production of fiber ball filter media mainly relies on manual or semi-automated processes: operators first pull out rolled fiber bundles and cut them into fiber segments of predetermined lengths, then fold and bundle them into balls. This traditional production method has the following significant drawbacks:

[0004] 1. Poor precision in fixed-length shearing affects the consistency of filter media performance.

[0005] During manual cutting, operators rely on visual inspection or measuring tools to roughly determine the length of the fiber bundle. Because the fiber bundles are soft and easily deformed, elastic stretching occurs during straightening and measurement, resulting in a cutting length error often within ±5-10mm. Fiber segments of inconsistent length lead to significant differences in the diameter, filtration accuracy, and dirt-holding capacity of the resulting filter media, making it difficult to meet the uniformity requirements of wastewater treatment processes.

[0006] 2. The shaping of the balls relies on manual labor, which is inefficient and labor-intensive.

[0007] Bundling fiber segments into balls requires delicate actions such as folding, bundling, and knotting. Skilled workers take about 15-20 seconds per piece, and prolonged repetitive work can easily lead to hand fatigue, making it difficult to improve production efficiency. More importantly, the tightness of manual bundling varies from person to person and from time to time, causing large fluctuations in the porosity and compressive modulus of the same batch of products, which directly affects the filtration effect and backwashing performance after filling.

[0008] 3. Lack of automated continuous operation capability

[0009] The current production model is a two-stage discrete operation of "cutting first and then bundling". The cut fiber segments need to be manually transferred to the bundling station, resulting in poor coordination between processes and preventing the formation of a continuous production line. This not only increases the cost of work-in-process inventory and manual handling, but also limits further capacity expansion.

[0010] Therefore, developing a continuous production method that integrates precise cutting of fiber bundles to a fixed length with automated ball forming to solve the problems of poor precision, low efficiency, and insufficient product consistency in existing processes has become a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0011] The purpose of this invention is to provide an automated method for fixed-length shearing and ball forming of fiber ball filter media, which can effectively solve the problems in the background art.

[0012] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0013] An automated method for fixed-length shearing and ball forming of fiber ball filter media includes the following specific steps: Step 1: Fiber bundle tension control and straightening conveying: After the fiber bundle is drawn out from the unwinding device, it passes through the tension control roller group and the straightening mechanism in sequence. The tension control roller group is driven by a servo motor to achieve constant tension output. The tension set value is pre-calibrated according to the material characteristics of the fiber bundle. The straightening mechanism adopts a multi-set variable angle guide wheel combination structure to continuously straighten the soft and easily deformable fiber bundle, so that the fiber bundle remains straight during subsequent conveying; Step 2: Precise length measurement and fixed-length shearing: After straightening, the fiber... The fiber bundle enters the length measuring station, where a laser displacement sensor and a high-precision rotary encoder work together to collect the displacement of the fiber bundle in real time. The control system calculates the shearing trigger timing based on the preset target shearing length value. When the displacement reaches the target value, it immediately sends a command to the shearing actuator. The shearing actuator uses a servo-driven disc shearing blade, and the response time meets the preset time threshold requirement, realizing rapid fixed-length segmentation of the fiber bundle. Step 3: Automatic collection and bundling of fiber segments: The sheared fiber segments enter a collection channel with a negative pressure adsorption function. The collection channel is equipped with multiple bundling partitions. The falling fiber segments are automatically bundled and sorted according to a preset number to form fiber bundles with a certain number of fibers. Simultaneously, negative pressure adsorption maintains the stability of the fiber bundles during transport. Step 4: Folding mechanism and ball forming: The sorted fiber bundles enter the folding station. The folding mechanism consists of two sets of relatively moving clamping fingers and a central positioning pin. The clamping fingers clamp both ends of the fiber bundle and move towards the positioning pin, achieving automatic folding of the fiber bundle. The folded fiber bundle is then pushed to the ball forming station, which uses a pneumatic bundling device. The bundling device uses biodegradable high-molecular-weight binding wire. The sub-filaments are pushed by a cylinder to wrap around the bent parts of the binding wire. The binding force is precisely controlled by a proportional valve. After binding, the knotting action is automatically completed. Step 5: Finished product output and quality inspection: After the fiber ball filter material is formed, it slides into the finished product collection container through the discharge slide. A vision inspection unit is set up next to the discharge slide. The vision inspection unit takes pictures of the passing fiber balls and analyzes key parameters such as the diameter, roundness and tightness of the binding of the fiber balls through image processing algorithms. Fiber balls with qualified parameters enter the qualified product channel, and fiber balls with unqualified parameters are sorted into the unqualified product channel.

[0014] Preferably, in step 1, the tension control roller group includes several groups of active rollers and driven rollers. The speed control accuracy of the servo motor is within a preset accuracy range. The tension sensor monitors the tension value of the filament bundle in real time. When the tension deviation exceeds the preset tension deviation range, the speed of the servo motor is automatically adjusted for compensation.

[0015] Preferably, the straightening mechanism in step 1 includes multiple sets of variable angle guide wheels. The adjustable angle of each set of guide wheels is within a preset angle range. The surface of the guide wheels is covered with a rubber anti-slip layer, and the hardness of the rubber is within a preset hardness range to protect the surface of the fiber bundle from damage.

[0016] Preferably, in step 2, the measurement accuracy of the laser displacement sensor is within a preset accuracy range, the resolution of the rotary encoder meets the preset requirements, and the overall length measurement accuracy after data fusion is within a preset length measurement accuracy range, effectively overcoming the measurement error caused by the elastic stretching of the fiber bundle.

[0017] Preferably, in step 2, the disc shearing blade of the shearing actuator has a preset blade diameter, the blade material is cemented carbide, the cutting edge angle is a preset angle value, and the gap between the shearing blade and the lower blade groove is adjusted to a preset multiple of the fiber bundle diameter to ensure that the shearing surface is flat and burr-free.

[0018] Preferably, in step 3, the negative pressure adsorption pressure in the collection channel is within a preset adjustable range, the number of bundle separators can be changed and adjusted according to the required fiber ball specifications, and the number of fiber bundles corresponding to each bundle separator is within a preset number range.

[0019] Preferably, in step 4, the clamping fingers of the folding mechanism are made of polyurethane material with a preset hardness value and a preset width value. The clamping force is controlled within a preset air pressure control range by a pneumatic proportional valve to ensure effective clamping of the fiber bundle without causing injury.

[0020] Preferably, in step 4, the diameter of the binding wire of the pneumatic binding device is a preset wire diameter, the binding force control range is within a preset force control range, the knotting action is completed by a rotating twisting mechanism, the rotation speed is a preset rotation speed, and the knotting firmness reaches or exceeds a preset firmness threshold.

[0021] Preferably, in step 5, the visual inspection unit includes multiple industrial cameras and multiple ring light sources. The resolution of the cameras meets the preset resolution requirements, the field of view covers the preset field of view, and the image processing algorithm has a detection accuracy of fiber ball diameter within a preset detection accuracy range and a detection accuracy of roundness within a preset roundness detection accuracy range.

[0022] Preferably, in step 5, the non-conforming product sorting mechanism adopts an air-blowing sorting device, the sorting response time meets the preset sorting response time requirement, the sorting accuracy reaches the preset sorting accuracy requirement, and the qualified products and non-conforming products fall into different collection containers respectively.

[0023] Preferably, the unwinding device is further equipped with an automatic correction mechanism, and the correction sensor is an infrared photoelectric sensor. The correction accuracy is within the preset correction accuracy range, ensuring that the fiber bundle always runs along the predetermined trajectory during the unwinding process, and preventing the fiber bundle from deviating and affecting the subsequent processing accuracy.

[0024] The beneficial effects of this invention are: 1. High-precision fixed-length shearing

[0025] By using a laser displacement sensor and a high-precision rotary encoder for length measurement, and a servo-driven shearing mechanism with a response time that meets preset requirements, the fixed-length shearing accuracy of the fiber bundle is achieved within a preset accuracy range. Compared with the accuracy of traditional manual visual inspection or ruler-based methods within a preset error range, the shearing accuracy is significantly improved, which significantly improves the dimensional consistency and performance uniformity of the fiber ball filter media.

[0026] 2. Automated ball forming

[0027] The design combines a folding mechanism with a pneumatic bundling device to achieve automatic folding and bundling of fiber bundles. The bundling force is precisely controlled within a preset force control range by a proportional valve. The time for forming the bundle is reduced from the preset forming time range of traditional manual methods to within a preset forming time threshold, significantly improving efficiency. Furthermore, the tightness of the bundling remains highly consistent, and the porosity and compressive modulus fluctuations between product batches are controlled within a preset fluctuation range.

[0028] 3. Continuous production line integration

[0029] The process integrates tension control, straightening and conveying, precise length measurement, fixed-length shearing, fiber segment collection and bundling, folding and balling, and quality inspection into an automated continuous production line. The process is automatically connected, eliminating the need for manual transfer of work-in-process, effectively eliminating the accumulation of work-in-process and manual handling costs, and significantly improving production capacity compared to traditional discrete operation methods.

[0030] 4. Online quality control

[0031] A visual inspection unit is set up in the finished product output stage to detect key parameters such as the diameter, roundness and tightness of the fiber balls in real time. Defective products are automatically sorted out, which effectively ensures the quality stability of the products leaving the factory and reduces the risk of defective products flowing into subsequent application stages. Attached Figure Description

[0032] Figure 1This is a process flow diagram of the automated fixed-length shearing and ball-forming method for fiber ball filter media proposed in this invention. Detailed Implementation

[0033] 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.

[0034] Specific implementation examples are given below.

[0035] Example 1

[0036] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments.

[0037] This invention provides an automated fixed-length shearing and ball-forming method for fiber ball filter media. This method integrates five core processes: fiber bundle tension control and straightening conveying, precise length measurement and fixed-length shearing, automatic fiber segment collection and bundling, folding mechanism and ball-forming, finished product output and quality inspection. The control system realizes coordinated linkage and automated operation between the processes.

[0038] In the above-mentioned automated fixed-length shearing and ball-forming method for fiber ball filter media, step 1 is the fiber bundle tension control and straightening conveying stage. After the fiber bundle is drawn out from the unwinding device, it passes sequentially through the tension control roller group and the straightening mechanism. The tension control roller group achieves constant tension output through servo motor drive. The tension set value is pre-calibrated according to the material characteristics of the fiber bundle. The straightening mechanism adopts a multi-set variable-angle guide wheel combination structure to continuously straighten the soft and easily deformable fiber bundle, so that the bundle remains straight during subsequent conveying.

[0039] Specifically, the unwinding device is equipped with an automatic correction mechanism. The correction sensor is an infrared photoelectric sensor, and the correction accuracy is within a preset range. The infrared photoelectric sensor continuously monitors the offset of the fiber bundle relative to the predetermined trajectory, and the sensor signal is transmitted to the central control unit in real time. The central control unit calculates the correction adjustment amount based on the offset and sends a correction command to the correction execution mechanism of the unwinding device. The correction execution mechanism typically uses a linear guide rail combined with a servo drive. According to the correction command, it drives the unwinding shaft to make horizontal displacement adjustments, ensuring that the fiber bundle always runs along the predetermined trajectory during the unwinding process, preventing the fiber bundle from deviating and affecting the accuracy of subsequent processing. The unwinding device's core adopts an air-expansion shaft structure, which facilitates quick replacement of fiber bundle rolls of different specifications. The air-expansion shaft has an internal air pressure channel. By inflating the shaft sleeve, the core is tightened, and the roll can be easily replaced after depressurization.

[0040] Specifically, the tension control roller group includes several sets of driving rollers and driven rollers, and the speed control accuracy of the servo motor is within a preset accuracy range. Tension sensors monitor the fiber bundle tension value in real time, and automatically adjust the servo motor speed for compensation when the tension deviation exceeds the preset tension deviation range. The tension control roller group adopts a multi-roller collaborative tension control architecture, consisting of three parts: the inlet roller group, the intermediate roller group, and the outlet roller group. The inlet roller group is located between the unwinding device and the straightening mechanism, responsible for receiving the fiber bundle from the unwinding device and establishing initial tension; the intermediate roller group is located between the straightening mechanism and the subsequent length measuring station, playing a role in tension transmission and buffering; the outlet roller group is located at the entrance of the length measuring station, ensuring stable tension of the fiber bundle entering the length measuring station.

[0041] Tension sensors, employing either non-contact capacitive or contact pressure-sensitive sensors, are installed at the driven roller end of the tension control roller assembly. Capacitive tension sensors calculate tension by measuring the capacitance change between the fiber bundle and the sensor electrodes, while pressure-sensitive tension sensors calculate tension by measuring the radial pressure on the driven roller bearing housing. The tension signal is transmitted to the central control unit in the form of analog voltage or digital signal, with a control cycle typically set to 1 to 10 milliseconds. Tension control employs a closed-loop PID control algorithm, with proportional, integral, and derivative coefficients tuned according to the material properties of the fiber bundle. When the deviation between the actual tension value detected by the tension sensor and the preset target tension value exceeds a preset deviation range, the central control unit calculates the servo motor speed adjustment based on the PID control algorithm and sends a speed correction command to the servo driver via fieldbus or industrial Ethernet. Upon receiving the command, the servo driver drives the servo motor to adjust the speed of the drive roller, thereby changing the fiber bundle tension and quickly bringing the actual tension value back to the target range. The servo motor speed control accuracy is typically better than 0.1 revolutions per minute, ensuring the stability of tension control.

[0042] Specifically, the straightening mechanism includes multiple sets of variable-angle guide wheels. The adjustable angle of each set of guide wheels is within a preset angle range. The surface of the guide wheels is covered with a rubber anti-slip layer, and the rubber hardness is within a preset hardness range to protect the fiber bundle surface from damage. The straightening mechanism adopts a combination structure of multiple sets of variable-angle guide wheels, and the installation angle of each set of guide wheels can be independently adjusted according to the flexibility of the fiber bundle. Typically, 3 to 5 sets of guide wheels are set. From the inlet to the outlet direction, the angle between the axis of each set of guide wheels and the fiber bundle conveying direction increases or decreases sequentially, forming a gradual straightening trajectory. The guide wheel base is made of high-strength steel, and the surface is covered with a polyurethane rubber layer or silicone rubber layer with a Shore A55 to Shore A75 hardness. The rubber layer thickness is typically 2 to 5 millimeters. The presence of the rubber anti-slip layer increases the coefficient of friction between the guide wheels and the fiber bundle, preventing the bundle from slipping during conveying. Furthermore, the elastic properties of the rubber material can produce a gentle pressing effect on the fiber bundle, avoiding mechanical damage to the bundle surface during straightening.

[0043] The installation angle of each set of guide wheels is adjusted via precision adjusting screws or electric push rods, with an adjustment range typically between ±30 and ±45 degrees. The central control unit stores preset parameters for guide wheel angles for different fiber bundle materials. When changing fiber bundle specifications, the operator selects the corresponding material type through the human-machine interface, and the system automatically adjusts each set of guide wheels to the preset angle. The guide wheels are supported by deep groove ball bearings or angular contact ball bearings, with the radial clearance of the bearings controlled at C3 or C4 level to ensure flexible rotation and smooth operation. The rotational speed of the guide wheels is monitored in real time by a speed sensor, and the speed signal is fed back to the central control unit to monitor the operating status of the straightening mechanism.

[0044] After the fiber bundle enters the straightening mechanism, each set of variable-angle guide wheels applies lateral forces in different directions, gradually straightening the originally bent and twisted bundle. The fiber bundle advances along a serpentine path between the guide wheel sets, with its bending direction and degree corrected at each set. The straightened fiber bundle leaves the straightening mechanism with a high degree of straightness, providing stable transport conditions for subsequent accurate length measurement.

[0045] In the above-mentioned automated fixed-length shearing and ball forming method for fiber ball filter media, step 2 is the precise length measurement and fixed-length shearing stage. The straightened fiber bundles enter the length measurement station. A laser displacement sensor and a high-precision rotary encoder work together to collect the displacement of the fiber bundles in real time. The control system calculates the shearing trigger timing based on the preset target shearing length value. When the displacement reaches the target value, a command is immediately sent to the shearing actuator. The shearing actuator uses a servo-driven disc shearing blade, and the response time meets the preset time threshold requirement, achieving rapid fixed-length segmentation of the fiber bundles.

[0046] Specifically, the length measurement station is equipped with two measuring devices: a laser displacement sensor and a high-precision rotary encoder. These two devices work together to accurately acquire the displacement of the fiber bundle. The laser displacement sensor uses the triangulation principle. The sensor emits a focused laser beam that illuminates the surface of the fiber bundle, and the laser spot is imaged on a photosensitive element inside the sensor. As the fiber bundle moves along the conveying direction, the position of the laser spot on the photosensitive element changes accordingly. The sensor calculates the displacement of the fiber bundle relative to the sensor based on the position of the laser spot. The measurement accuracy of the laser displacement sensor is typically ±0.02 mm to ±0.05 mm, and the sampling frequency can reach 1 to 10 kHz, effectively responding to high-speed displacement changes in the fiber bundle.

[0047] A high-precision rotary encoder is installed on the drive roller shaft end on the exit side of the tension control roller assembly. It calculates the displacement of the fiber bundle by measuring the rotation angle of the drive roller. The surface of the drive roller is finely machined, with a diameter error controlled within 0.01 mm and a surface roughness Ra value better than 0.8 micrometers, ensuring no relative slippage between the fiber bundle and the drive roller. The rotary encoder is an incremental photoelectric encoder, typically with a resolution of 1000 to 5000 pulses per revolution, corresponding to a drive roller rotation angle resolution of 0.072 degrees to 0.36 degrees. When the drive roller diameter is 50 mm, the rotary encoder can achieve a displacement measurement resolution of 0.0157 mm to 0.0785 mm.

[0048] Data fusion between the laser displacement sensor and the rotary encoder employs a weighted average or Kalman filter algorithm. The central control unit simultaneously receives displacement signals from both the laser displacement sensor and the rotary encoder, calculating the overall displacement using the data fusion algorithm. The laser displacement sensor's advantage lies in directly measuring the actual position of the fiber bundle, effectively compensating for measurement errors caused by factors such as fiber bundle elasticity and roll slippage. The rotary encoder's advantage is its high measurement stability, unaffected by fiber bundle color, transparency, and surface reflectivity. Data fusion leverages the strengths of both, achieving an overall length measurement accuracy within ±0.05 mm, effectively overcoming measurement errors caused by fiber bundle elasticity.

[0049] The length measuring station is also equipped with a dedicated length measuring roller assembly, which consists of two parallel drive rollers. The distance between the two drive rollers is adjusted according to the width of the fiber bundle to ensure that the fiber bundle is stably held between the two drive rollers. The surface of the drive rollers of the length measuring roller assembly is coated with a layer of polyurethane or silicone rubber material with a hardness of Shore A60 to Shore A70 and a thickness of 3 to 8 mm, which increases the coefficient of friction between the drive rollers and the fiber bundle and prevents the fiber bundle from slipping during the length measuring process. The distance between the length measuring roller assembly and the shearing actuator is precisely calibrated according to the target shearing length and the system response time to ensure that the position where the fiber bundle is cut corresponds precisely to the displacement collected by the length measuring sensor.

[0050] The control system calculates the shearing trigger timing based on the preset target shearing length and the real-time collected comprehensive displacement. The control algorithm employs a predictive control strategy, comprehensively considering the current displacement velocity, system response delay, and the acceleration / deceleration characteristics of the shearing actuator. It anticipates the moment when the fiber bundle will reach the target shearing length and sends a shearing command to the shearing actuator. Accurate calculation of the shearing trigger timing is crucial for ensuring the precision of fixed-length shearing. The calculation formula is as follows:

[0051] ,

[0052] in, This is the trigger distance from the target shearing position. For the target shear length, The current displacement velocity, For system response time, The deceleration and braking time of the shearing actuator. When the real-time displacement reaches... At that moment, the control system immediately sends a shearing command to the shearing actuator.

[0053] Specifically, the shearing actuator employs a servo-driven disc shear, comprising a cutter head, cutter shaft, servo motor, and reducer. The cutter head is made of carbide, typically with a diameter of 80 to 150 mm and a thickness of 3 to 8 mm. The outer circumference of the cutter head is precision ground, with a cutting edge angle of 25 to 35 degrees and a cutting edge sharpness controlled within 0.01 mm. The cutter head is fixed to the cutter shaft via a key connection. The cutter shaft is driven by the servo motor through a precision reducer, enabling high-speed start / stop and precise position control. The disc shear and the lower cutting groove form a shearing pair. The lower cutting groove is fixed to the frame, and its opening size matches the thickness of the cutter head. The lower cutting groove is also made of carbide or high-speed steel, offering high wear resistance and a long service life.

[0054] The response time of the shearing actuator meets the preset time threshold requirements, typically controlled within 50 to 200 milliseconds. The servo motor is a high-dynamic-response permanent magnet synchronous servo motor with a rated speed of 2000 to 5000 rpm and an acceleration / deceleration time constant of less than 50 milliseconds. The reducer uses a low-backlash precision planetary reducer or harmonic reducer with a backlash of less than 3 arcminutes to ensure the positioning accuracy of the cutter head. The shearing actuator is also equipped with a displacement sensor to monitor the real-time position of the cutter head, achieving closed-loop control.

[0055] The gap between the shearing blade and the lower blade groove is adjusted to a preset multiple of the fiber bundle diameter, typically 0.8 to 1.2 times. Too small a gap will increase shearing resistance and accelerate blade wear, while too large a gap will result in uneven sheared surfaces and increased burrs. Precisely adjusting the gap to a reasonable range ensures a smooth, burr-free sheared surface. After shearing, the control system records the shearing position data and timestamp for subsequent quality traceability and statistical analysis.

[0056] In the above-mentioned automated fixed-length shearing and ball forming method for fiber ball filter media, step 3 is the automatic collection and bundling stage of fiber segments. The sheared fiber segments enter a collection channel with negative pressure adsorption function. The collection channel is equipped with multiple bundling baffles, which automatically bundle and arrange the falling fiber segments according to a preset number to form fiber bundle groups containing a certain number of fibers. At the same time, the negative pressure adsorption maintains the morphological stability of the fiber bundle groups during the transportation process.

[0057] Specifically, the collection channel is located below the shearing station and connects to the lower blade groove of the shearing actuator. After the fiber bundle is cut, the fiber segments at the break point fall naturally under gravity and into the inlet of the collection channel. The inlet of the collection channel is trapezoidal or trumpet-shaped, with a width slightly larger than the width of the fiber bundle, effectively accommodating the falling fiber segments and preventing them from scattering. The side and bottom walls of the collection channel are made of stainless steel with a polished surface to reduce frictional resistance between the fiber segments and the channel walls.

[0058] A negative pressure adsorption effect is generated inside the collection channel. The negative pressure source is typically a centrifugal fan or a Roots blower, which is connected to the negative pressure chamber of the collection channel via a pipe. Several evenly distributed suction holes are opened on the side wall of the collection channel, with a diameter typically 2 to 5 mm and an opening ratio controlled between 15% and 25%. The pressure inside the negative pressure chamber is lower than atmospheric pressure, with a pressure difference typically between 500 and 2000 Pascals. The negative pressure airflow enters the collection channel through the suction holes, forming a uniform centripetal airflow field within the channel. After entering the collection channel, the fiber segments are adsorbed by the negative pressure airflow and firmly adsorbed onto the channel wall or suspended in the airflow field, effectively preventing the fiber segments from entangled or accumulating.

[0059] The collection channel is equipped with multiple bundle-splitting baffles, arranged along the channel's extension direction, dividing the channel's interior into several parallel bundle-splitting slots. The number of baffles can be adjusted according to the required fiber ball specifications, typically ranging from 4 to 12 sets. Each bundle-splitting baffle corresponds to one bundle-splitting slot, and the width of each slot is designed based on the number and diameter of the fiber bundles. When fiber segments fall into the collection channel, negative pressure airflow evenly disperses and guides them into each bundle-splitting slot. Because the bundle-splitting slots are isolated from each other, the fiber segments aggregate independently within each slot, preventing cross-splitting mixing.

[0060] The fiber bundle separators are made of engineering plastics such as polyoxymethylene, nylon, or polyurethane, offering excellent wear resistance and chemical stability. The separators are detachably connected to the collection channel walls, facilitating separator configuration changes based on different fiber ball specifications. Each fiber bundle separator corresponds to a preset number of fibers, typically 10 to 50. When the number of fiber segments gathered in a bundle slot reaches the preset value, the system detects that the slot is full via a photoelectric sensor or weighing sensor, and then triggers the action of pushing the fiber segments in that slot to the next station.

[0061] The pushing mechanism is located at the end of each fiber slot and is driven by a cylinder or linear motor. The cylinders are either standard or miniature cylinders, typically with a diameter of 16 to 40 mm, and the stroke is determined by the length of the fiber slot. When the photoelectric sensor detects that the fiber slot is full, the control system sends a push command to the pushing cylinder, causing the piston rod to extend and push the fiber segment out of the slot as a whole. The pushing mechanism is also equipped with limit switches to confirm that the pushing action has been completed.

[0062] Negative pressure adsorption maintains the morphological stability of the fiber bundle assembly during the conveying process. As fiber segments gather in the bundling groove, a continuous negative pressure airflow acts on the surface of the fiber segments, causing them to compact and adhere tightly to each other, forming a stable fiber bundle assembly. After leaving the bundling groove, the fiber bundle assembly moves along the conveying channel to the next station under the action of a pushing force. Throughout this movement, the negative pressure adsorption continues, ensuring that the fiber bundle assembly does not scatter or deform during conveying.

[0063] The collection channel is also equipped with a cleaning mechanism and a waste recycling mechanism. The cleaning mechanism uses high-pressure airflow or brush cleaning devices to periodically remove fiber debris adhering to the inner wall of the collection channel and the bundling partitions, preventing debris accumulation from affecting bundling accuracy and negative pressure effect. The waste recycling mechanism collects the cleaned fiber debris into a waste bin for centralized processing.

[0064] In the above-mentioned automated fixed-length shearing and ball-forming method for fiber ball filter media, step 4 is the folding mechanism and ball-forming stage. The fiber bundles after sorting and bundling enter the folding station. The folding mechanism consists of two sets of relatively moving clamping fingers and a central positioning pin. The clamping fingers clamp both ends of the fiber bundle and move towards the positioning pin, achieving automatic folding of the fiber bundle. The folded fiber bundle is then pushed to the ball-forming station, which uses a pneumatic binding device. The binding thread of the binding device is biodegradable polymer thread. A cylinder pushes the binding thread to wrap around the folded area. The binding force is precisely controlled by a proportional valve, and the knotting action is automatically completed after binding.

[0065] Specifically, the folding station is located at the core of the folding mechanism, and its structural layout is symmetrical. A central positioning pin is fixedly installed in the center of the station, with its axis perpendicular to the conveying direction of the fiber bundle assembly. The diameter of the positioning pin is selected according to the size of the target fiber ball, typically 10 to 30 millimeters. The surface of the positioning pin is hardened to a hardness of HRC55 to HRC60, with a surface roughness Ra value better than 0.8 micrometers, ensuring sufficient wear resistance and lubricity to reduce frictional resistance between the fiber bundle assembly and the positioning pin during the folding process.

[0066] The folding mechanism has two sets of clamping fingers, located on either side of the positioning pin. Each set of clamping fingers contains two to four long, slender fingers, typically 50 to 150 mm long, 10 to 30 mm wide, and 3 to 8 mm thick. The clamping fingers are made of polyurethane with a preset hardness value, typically Shore A70 to Shore A90. Polyurethane has good elasticity and abrasion resistance, providing sufficient clamping force without damaging the fiber bundle. The clamping width of the clamping fingers is a preset value, and the spacing between the fingers is adjusted according to the width of the fiber bundle group, typically 0.8 to 1.0 times the width of the fiber bundle group.

[0067] Two sets of clamping fingers are mounted on two sliding platforms, which are driven by linear guides and cylinders or servo motors. The cylinders are double-acting or multiplier cylinders, providing the horizontal movement power for the clamping fingers. When the fiber bundle is conveyed to the folding station, the control system detects the position signal of the fiber bundle and sends clamping commands to the cylinders of both sets of clamping fingers. The cylinders on both sides simultaneously drive the clamping fingers to move towards the fiber bundle, clamping both ends of the fiber bundle when they reach the predetermined position. The clamping force is controlled within a preset air pressure control range by a pneumatic proportional valve, typically from 0.2 to 0.6 MPa. The pneumatic proportional valve is a high-precision electro-proportional valve, capable of adjusting the output air pressure in real time based on feedback signals to ensure consistent clamping force. After clamping, the clamping fingers remain clamped and begin moving towards the positioning pin.

[0068] The folding process is as follows: After clamping both ends of the fiber bundle, the gripping fingers on both sides move towards the positioning pin simultaneously, centered on the pin. Because the two ends of the fiber bundle are fixed by the gripping fingers, the middle part gradually moves towards the positioning pin during the movement, eventually completing the fold at the pin. After the fiber bundle passes around the positioning pin, both ends are located on either side of the pin, forming a U-shaped fold. After the fold is complete, the folding mechanism detects that the fiber bundle has reached the predetermined position, releases the gripping fingers, and releases the folded fiber bundle.

[0069] The folding mechanism is also equipped with position and force sensors to monitor the real-time position and clamping force of the gripping fingers. The position sensors typically employ magnetic or optical non-contact sensors with a detection accuracy better than 0.1 mm. The force sensor is positioned between the base of the gripping finger and the cylinder piston rod to monitor pressure changes during clamping, preventing excessive clamping force from damaging the fiber bundle. When the pressure detected by the force sensor exceeds a preset threshold, the control system immediately issues an alarm signal and stops the clamping action.

[0070] The folded fiber bundle is pushed to the bundling station. A pushing mechanism, driven by a cylinder or linear motor, is located between the folding and bundling stations. The pusher head of the pushing mechanism is made of polyurethane or nylon and its shape matches the cross-section of the folded fiber bundle. The pushing action is coordinated with the folding action, and the pushing is performed immediately after folding to ensure that the fiber bundle is smoothly pushed to the bundling station while maintaining its folded state.

[0071] Specifically, the bundling station is equipped with a pneumatic bundling device for bundling folded fiber bundles. The core components of the pneumatic bundling device include bundling thread, a thread feeding mechanism, a tensioning mechanism, and a knotting mechanism. The bundling thread is a biodegradable polymer filament with a preset diameter, typically 0.3 to 0.8 mm. The thread material is selected from biodegradable polymers such as polyglycolic acid, polylactic acid, or polycaprolactone, exhibiting good biocompatibility and environmental friendliness. The tensile strength of the biodegradable polymer filament is typically 300 to 600 MPa, with an elongation at break of 10% to 30%, meeting the bundling strength requirements.

[0072] The wire feeding mechanism is located between the wire reel and the tensioning mechanism and is driven by a servo motor. The mechanism includes a feeding wheel and a pressing wheel, with the feeding wheel being the driving wheel and the pressing wheel being the driven wheel. The gap between them is slightly smaller than the wire diameter, and the wire is fed to the tensioning mechanism through friction. The speed and direction of the wire feeding motor are precisely controlled according to the bundling process requirements to ensure that the wire feeding length and speed meet the process requirements.

[0073] The tensioning mechanism is cylinder-driven, pushing the wire around the bend to achieve a wrapping. The cylinder's thrust is precisely controlled by a proportional valve, with the wrapping force controlled within a preset range, typically 5 to 30 Newtons. The proportional valve, either electric or servo-driven, adjusts the cylinder's output pressure in real time based on the set value and feedback signal, ensuring consistent wrapping force each time. Once the wire has wrapped a predetermined number of times, the tensioning mechanism stops tensioning, maintaining the wire under tension.

[0074] The knotting action is accomplished using a rotary stranding mechanism at a preset rotation speed. This mechanism includes a rotary motor and a stranding hook. The motor drives the hook to rotate, wrapping and tightening the end of the wire to form a secure knot. The rotation speed of the mechanism is typically 500 to 2000 revolutions per minute, with the rotation time determined by the wire diameter and material. After rotation, the stranding hook returns to its original position, and the wire is securely bound to the bend in the fiber bundle. The knot's strength must exceed a preset threshold, typically requiring the knot to withstand a tensile force of at least 20 Newtons without loosening.

[0075] The fiber ball bundling station is also equipped with a material level sensor and a finished product detection sensor. The material level sensor detects whether there are fiber bundles to be bundled in the station to prevent empty or repetitive operations. The finished product detection sensor detects the size and shape of the bundled fiber balls. Once the bundling quality is confirmed to be up to standard, it triggers an ejection action to push the finished fiber balls to the discharge chute.

[0076] During the bundling process, the binding wire typically wraps 2 to 4 times around the folded section, with the specific number determined by the specifications and strength requirements of the fiber ball. The winding direction can be clockwise or counterclockwise, depending on the structure of the knotting mechanism. After each wrap, the tensioning mechanism performs a tensioning action, gradually tightening the wire to the predetermined tightness. After the final tensioning, the rotating stranding mechanism starts, completing the knotting action. The timing of the entire bundling process is precisely controlled by the central control unit, with the timing error of each actuator controlled within 10 milliseconds to ensure consistent bundling quality.

[0077] In the above-mentioned automated fixed-length shearing and balling method for fiber ball filter media, step 5 is the finished product output and quality inspection stage. After balling, the fiber ball filter media slides into the finished product collection container through a discharge chute. A vision inspection unit is installed beside the discharge chute. The vision inspection unit takes pictures of the passing fiber balls and analyzes key parameters such as the diameter, roundness, and balling tightness of the fiber balls using image processing algorithms. Fiber balls with qualified parameters enter the qualified product channel, while fiber balls with unqualified parameters are sorted into the unqualified product channel.

[0078] Specifically, the discharge chute is located downstream of the ball-forming station. Its structure is an inclined rectangular channel, typically with an inclination angle of 30 to 60 degrees. The fiber balls slide downwards along the discharge chute under the combined effects of gravity and the chute's inclination. The sliding speed is controlled by adjusting the chute's inclination angle and the roughness of its inner surface. The inner surface of the chute is made of smooth stainless steel or coated with polytetrafluoroethylene (PTFE) to reduce frictional resistance between the fiber balls and the chute. The chute outlet has two branches: a qualified product channel and a non-qualified product channel, which are switched by a baffle or flap mechanism.

[0079] The vision inspection unit is located beside the discharge chute and includes multiple industrial cameras and multiple ring light sources. The industrial cameras are high-resolution area scan or line scan cameras, with resolution meeting preset requirements, typically ranging from 2 to 12 megapixels. The camera lenses are either telecentric or standard lenses, the specific type determined by the field of view and required inspection accuracy. The ring light sources are coaxial or dome light sources, typically using white, blue, or infrared light, and their brightness can be adjusted via a controller.

[0080] The vision inspection unit takes pictures of the passing fiber balls. When a fiber ball slides along the discharge chute into the camera's field of view, a trigger sensor detects the fiber ball's position signal and sends a shooting trigger signal to the camera. The camera completes exposure and image acquisition within a very short time after receiving the trigger signal, and the acquired image data is transmitted to an image processing industrial control computer. The image processing algorithm analyzes and processes the acquired image, extracting the geometric and texture features of the fiber balls.

[0081] The image processing algorithm first preprocesses the original image, including denoising, contrast enhancement, and background segmentation. Denoising uses Gaussian filtering or median filtering, contrast enhancement uses histogram equalization or gamma correction, and background segmentation uses thresholding or edge detection algorithms. After preprocessing, the algorithm enters the feature extraction stage, mainly extracting the following types of features: the detection accuracy of the fiber ball diameter is within a preset range, and the detection accuracy of roundness is within a preset range.

[0082] The diameter of the fiber ball is measured using edge detection and circle fitting algorithms. First, the outer contour edges of the fiber ball are extracted using an edge detection algorithm, which can employ the Canny operator, Sobel operator, or a deep learning-based edge detection network. After extracting the edge points, a circle is fitted using the least squares method or a random sample consensus algorithm to calculate the center and radius of the circle. The accuracy of the circle fitting is typically better than 0.1 mm, meeting the accuracy requirements for fiber ball diameter measurement.

[0083] The roundness of fiber balls is evaluated using a roundness error calculation method. Roundness error is defined as the maximum deviation between the actual outline of the fiber ball and the fitted circle. This is achieved by calculating the distance from each edge point to the center of the fitted circle, and taking the difference between the maximum and minimum distances as the roundness error value. A smaller roundness error indicates that the fiber ball's shape is closer to a perfect sphere. The threshold for roundness error is set according to product standards, typically requiring that the roundness error not exceed 5% to 10% of the diameter.

[0084] The tightness of the fiber ball binding is evaluated using a texture analysis algorithm. Binding tightness directly affects the elasticity and porosity of the fiber balls; appropriately tight fiber balls exhibit good filtration performance and backwash regeneration capabilities. The evaluation method for binding tightness includes surface texture feature extraction and compression characteristic analysis. Surface texture feature extraction involves performing frequency domain analysis or Gabor filtering on the fiber ball surface image to extract characteristic parameters such as texture directionality, uniformity, and roughness. Compression characteristic analysis involves applying a predetermined pressure to the fiber balls and measuring their deformation to calculate the compressive stiffness and resilience coefficient. The combined analysis results of texture features and compression characteristics are used to determine whether the binding tightness meets the requirements.

[0085] The vision inspection unit's field of view covers a preset range, ensuring that the entire fiber ball can be captured. Multiple industrial cameras photograph the fiber ball from different angles, typically three to five cameras arranged in a ring, acquiring images of the fiber ball from multiple perspectives such as horizontal, tilted, and top views. The images captured by each camera are processed using stitching or fusion algorithms to obtain complete three-dimensional information or a high-resolution two-dimensional image of the fiber ball.

[0086] The image processing algorithm analyzes key parameters such as fiber ball diameter, roundness, and binding tightness, and then compares the analysis results with preset acceptance standards. These preset standards include a lower limit for diameter, an upper limit for diameter, an upper limit for roundness error, and lower and upper limits for binding tightness. The lower limit for diameter is typically 0.9 times the target diameter, and the upper limit for diameter is typically 1.1 times the target diameter; the upper limit for roundness error is typically 8% of the diameter; binding tightness is determined based on a comprehensive score of texture features and compression characteristics, and a score exceeding a set threshold is considered acceptable.

[0087] Fiber balls that meet the required parameters enter the qualified product channel. Once the vision inspection unit determines that the fiber ball is qualified, the control system sends a switching command to the baffle actuator of the discharge chute. The baffle adjusts to the qualified product channel position, and the fiber ball slides into the qualified product collection container. The qualified product collection container is usually a plastic or metal basket, and the container is labeled with product specifications and production date information to facilitate subsequent packaging and warehousing management.

[0088] Fiber balls that do not meet the parameter requirements are sorted into the defective product channel. The defective product sorting mechanism uses an air-blowing sorting device, with a sorting response time that meets the preset requirements and a sorting accuracy that meets the preset requirements. When the vision inspection unit determines that a fiber ball is defective, the control system sends a sorting command to the sorting execution mechanism. The air-blowing sorting device includes a compressed air source, a solenoid valve, and nozzles. Upon receiving the sorting command, the solenoid valve opens rapidly, and compressed air is sprayed through the nozzles onto the defective fiber balls. The airflow impact force propels the fiber balls from the discharge chute to the defective product collection container. The response time of the air-blowing sorting device is typically less than 50 milliseconds, and the sorting accuracy can reach over 99%. Qualified and defective products fall into different collection containers, facilitating subsequent quality analysis and improvement.

[0089] The vision inspection unit also features statistical and traceability functions. The system automatically records the inspection image, inspection parameters, and judgment results for each fiber ball, forming a complete quality inspection database. Through statistical analysis of the inspection data, the quality status of the production line can be monitored in real time, allowing for timely detection and resolution of quality issues. The inspection data can be exported and printed, and used for quality report preparation and customer delivery.

[0090] The control system in this embodiment adopts an architecture combining a programmable logic controller (PLC) and an industrial touchscreen. The PLC is responsible for real-time control and data acquisition of each actuator, while the industrial touchscreen is responsible for human-machine interaction and parameter setting. The control system has two operating modes: manual and automatic. In manual mode, the operator can individually control the actions of each actuator, facilitating equipment debugging and troubleshooting. In automatic mode, the system runs automatically according to a preset process flow, achieving fully automated production.

[0091] This embodiment also relates to a specific application example of an automated fixed-length shearing and ball-forming method for fiber ball filter media. In a typical application scenario, the fiber bundle to be processed is made of polyester fiber, with a bundle width of 50 mm, a bundle thickness of 0.5 mm, and a length of 5000 meters per roll. The target fiber ball has a diameter of 65 mm, each fiber ball consists of 25 fiber bundles, and the shearing length is 130 mm.

[0092] After the production line starts, the unwinding device unfolds the fiber bundle roll. A web-alignment sensor monitors the lateral position deviation of the bundle in real time, and the web-alignment actuator automatically adjusts the horizontal position of the unwinding shaft based on the deviation signal, ensuring the bundle always runs along the predetermined trajectory. Once the fiber bundle enters the tension control roller group, the initial tension value detected by the tension sensor is compared with the preset target tension value. The central control unit adjusts the servo motor speed using a PID algorithm to stabilize the tension within the preset range. The target tension value for polyester fiber bundles is typically set between 20 and 50 Newtons, with the specific value determined based on the bundle's tensile characteristics and processing speed.

[0093] After initial tensioning by the tension control rollers, the fiber bundle enters the straightening mechanism. The straightening mechanism comprises four sets of variable-angle guide rollers, each with its installation angle preset and adjusted according to the flexibility of the polyester fiber. The polyurethane rubber layer on the guide roller surface is set to Shore A65 hardness and has a thickness of 4 mm. Under the progressive straightening action of the four sets of guide rollers, the originally bent and twisted fiber bundle gradually becomes straight, achieving a straightness that meets the requirements of the subsequent length measurement station.

[0094] The straightened fiber bundles enter the length measuring station. A laser displacement sensor at the length measuring station continuously scans the surface of the fiber bundle, with a sampling frequency set to 5 kHz and a measurement accuracy of ±0.03 mm. A high-precision rotary encoder synchronously acquires the rotation signal of the drive roller, with a resolution of 2048 pulses per revolution, corresponding to a displacement measurement resolution of 0.038 mm. The two measurement signals are fused using a Kalman filter algorithm, achieving a combined length measuring accuracy of ±0.05 mm.

[0095] The central control unit calculates the shearing trigger timing based on the target shearing length and real-time displacement. When the fiber bundle displacement reaches the trigger distance, the control system sends a shearing command to the shearing actuator. The servo motor of the disc shearing blade drives the blade disc to rotate at a speed of 3000 rpm, with a response time of less than 100 milliseconds. The disc shearing blade has a blade disc diameter of 100 mm, a cutting edge angle of 30 degrees, and the blade material is cemented carbide. The gap between the shearing blade and the lower cutting groove is adjusted to 1.0 times the thickness of the fiber bundle, i.e., 0.5 mm. After the shearing action is completed, the fiber bundle is precisely cut into fiber segments of 130 mm in length, with the shearing length error controlled within ±0.1 mm.

[0096] The cut fiber segments fall into the collection channel. A negative pressure airflow generated by a negative pressure fan enters the collection channel through the suction port, with the negative pressure set at 1200 Pascals. Eight bundle-forming baffles within the collection channel separate the fiber segments into eight bundle slots, each slot corresponding to 25 fiber segments, forming a fiber bundle group. When a photoelectric sensor detects that the number of fiber segments in a bundle slot has reached 25, the control system sends a push command to the push cylinder, which then pushes the fiber bundle group into the conveying channel.

[0097] The fiber bundle assembly enters the folding station along the conveyor channel. The clamping fingers of the folding mechanism are made of polyurethane with a Shore A80 hardness and a clamping width of 20 mm. The clamping force is controlled at 0.4 MPa by a pneumatic proportional valve. After the clamping fingers clamp both ends of the fiber bundle assembly, they move towards the central positioning pin under the drive of a cylinder. The positioning pin has a diameter of 20 mm. After the fiber bundle assembly passes around the positioning pin, it is folded in half, forming a U-shaped fold. After folding, the pushing mechanism pushes the folded fiber bundle assembly to the balling station.

[0098] The pneumatic bundling device at the bundling station bundles the folded fiber bundles. The biodegradable polymer threads are 0.5 mm in diameter and made of polyglycolic acid. A thread feeding mechanism delivers the threads to a tensioning mechanism, where a cylinder pushes the threads around the folded section three times. The bundling force is precisely controlled at 15 Newtons via a proportional valve. After tensioning, a rotating stranding mechanism completes the knotting action at a speed of 1200 revolutions per minute, achieving a knot strength exceeding 30 Newtons. The resulting bundled fiber balls are approximately 65 mm in diameter and spherical in shape.

[0099] The fiber ball slides down the discharge chute, and a vision inspection unit checks its quality. Three industrial cameras capture images of the fiber ball from different angles, while a ring light source provides uniform illumination. Image processing algorithms analyze the fiber ball's diameter, roundness, and bundling tightness. The diameter measurement is 65.2 mm, the roundness error is 1.8 mm, and the overall bundling tightness score is 92 points, all within the acceptable range. The system determines the fiber ball to be a qualified product, the baffle switches to the qualified product channel position, and the fiber ball slides into the qualified product collection container.

[0100] In another application scenario, the fiber tow material is polypropylene fiber, with a tow width of 40 mm and a target fiber ball diameter of 45 mm. Each fiber ball consists of 16 fiber tows, with a shearing length of 90 mm. Various parameters of the production line were adjusted according to the material characteristics of the polypropylene fiber: the tension setting was adjusted to 15-40 Newtons, the guide wheel angle was reset based on the flexibility of the polypropylene fiber, the sampling frequency of the laser displacement sensor was adjusted to 4 kHz, and the cutting edge angle of the disc shear was adjusted to 28 degrees. The diameter of the binding wire at the ball-binding station was adjusted to 0.4 mm, and the binding force was controlled at 12 Newtons. The pass / fail criteria of the vision inspection unit were adjusted accordingly based on the target diameter of 45 mm. Production results showed that the diameter uniformity, roundness, and ball-binding quality of the fiber balls all met the process requirements, with a product pass rate exceeding 99.5%.

[0101] This embodiment achieves high-precision fixed-length shearing and automated ball forming of fiber ball filter media through the above technical solutions, improving production efficiency and product quality consistency, and providing reliable technical support for the industrial production of fiber ball filter media.

[0102] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An automated method for fixed-length shearing and ball forming of fiber ball filter media, characterized in that, Includes the following steps: After the fiber bundle is drawn out from the unwinding device, it passes through the tension control roller group and the straightening mechanism in sequence. The tension control roller group is driven by a servo motor to achieve constant tension output. The tension setting value is pre-calibrated according to the material characteristics of the fiber bundle. The straightening mechanism adopts a combination structure of multiple variable angle guide wheels to continuously straighten the fiber bundle, so that the fiber bundle remains straight during subsequent conveying. After being straightened, the fiber bundles enter the length measuring station. The displacement of the fiber bundles is collected in real time through the collaborative work of a laser displacement sensor and a rotary encoder. The control system calculates the shearing trigger time based on the preset target shearing length value. When the displacement reaches the target value, it sends a command to the shearing actuator. The shearing actuator uses a servo-driven disc shearing blade to achieve rapid fixed-length segmentation of the fiber bundles. After being cut, the fiber segments enter a collection channel with a negative pressure adsorption function. The collection channel is equipped with multiple bundle-bundling partitions, which automatically bundle and organize the fiber segments according to a preset number, forming fiber bundle groups containing a certain number of fibers. The fiber bundle groups enter the folding station. The folding mechanism consists of two sets of relatively moving clamping fingers and a central positioning pin. After the clamping fingers clamp the two ends of the fiber bundle group, they move towards the positioning pin to realize the automatic folding of the fiber bundle group. The folded fiber bundle group is pushed to the ball-binding station. The ball-binding station uses a pneumatic binding device. The binding wire of the binding device is a biodegradable polymer thread. The cylinder pushes the binding wire to wrap around the bent part and binds it. The binding force is precisely controlled by a proportional valve. After being formed into balls, the fiber ball filter media slides into the finished product collection container through the discharge chute. A visual inspection unit is set up next to the discharge chute to detect the diameter, roundness, and tightness of the fiber balls. Fiber balls with qualified parameters enter the qualified product channel, while fiber balls with unqualified parameters are sorted into the unqualified product channel.

2. The method according to claim 1, characterized in that, The tension control roller assembly includes an active roller and a driven roller. The speed control accuracy of the servo motor meets the preset accuracy requirements. The tension sensor monitors the tension value of the filament bundle in real time. When the tension deviation exceeds the preset tension deviation range, the servo motor speed is automatically adjusted for compensation.

3. The method according to claim 1, characterized in that, The straightening mechanism includes multiple sets of variable angle guide wheels. The adjustable angle of each set of guide wheels is within a preset angle range. The surface of the guide wheels is covered with a rubber anti-slip layer to protect the surface of the fiber bundle from damage.

4. The method according to claim 1, characterized in that, The measurement accuracy of the laser displacement sensor meets the preset accuracy requirements, the resolution of the rotary encoder meets the preset requirements, and the overall length measurement accuracy after data fusion meets the preset length measurement accuracy requirements, effectively overcoming the measurement error caused by the elastic stretching of the fiber bundle.

5. The method according to claim 1, characterized in that, The disc shearing blade of the shearing actuator has a preset blade diameter, the blade material is cemented carbide, the cutting edge angle is a preset angle value, and the gap between the shearing blade and the lower blade groove is adjusted to a preset multiple of the fiber bundle diameter to ensure that the shearing surface is flat and burr-free.

6. The method according to claim 1, characterized in that, The negative pressure adsorption pressure in the collection channel is within a preset adjustable range. The number of bundle separators is adjusted according to the required fiber ball specifications, and the number of fiber bundles corresponding to each bundle separator is within a preset range.

7. The method according to claim 1, characterized in that, The clamping fingers of the folding mechanism are made of polyurethane, with a hardness within a preset hardness range, a clamping width within a preset width range, and a clamping force controlled by a pneumatic proportional valve within a preset pneumatic control range.

8. The method according to claim 1, characterized in that, The diameter of the binding wire in the pneumatic binding device is within a preset range, the binding force control range is within a preset range, the knotting action is completed by a rotating twisting mechanism, the rotation speed is within a preset range, and the knotting firmness reaches or exceeds a preset firmness threshold.

9. The method according to claim 1, characterized in that, The vision inspection unit includes multiple industrial cameras and multiple ring light sources. The resolution of the cameras meets the preset resolution requirements, the field of view covers the preset field of view, and the image processing algorithm has a detection accuracy of fiber ball diameter within the preset detection accuracy range and a detection accuracy of roundness within the preset roundness detection accuracy range.

10. The method according to claim 1, characterized in that, The unwinding device is equipped with an automatic correction mechanism. The correction sensor is an infrared photoelectric sensor, and the correction accuracy is within the preset correction accuracy range, ensuring that the fiber bundle always runs along the predetermined trajectory during the unwinding process.

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