METHOD FOR MANUFACTURING BRUSHS AND BRUSH MANUFACTURING MACHINE

Description

[0001] The invention relates to a method for producing brushes and a brush manufacturing machine.

[0002] For the economical production of brushes, it is necessary to achieve the highest possible technical availability of the brush production machines used and to avoid unplanned downtimes of the brush production machines.

[0003] DE 196 00 192 A1 discloses a method for monitoring a brush tucking machine comprising a brush carrier for holding a brush body with bristle holes, each of which is aligned with a tucking axis, a slider which is movable back and forth on a slider guide in the direction of the tucking axis and carries a tool head which can be placed against the brush body, a ram channel which extends along the tucking axis through the slider and the tool head and has a first inlet for a fastening means and a second inlet for bristle bundles, a bundle conveyor for conveying one bristle bundle at a time from a bristle supply to the second inlet, a ram which is movable back and forth in the ram channel along the tucking axis between a rest position in which it is retracted behind the first inlet and a tucking position in which it protrudes from the tool head to engage in a bristle hole,and a device for switching off the brush tamping machine when a predetermined driving force required to move the ram is exceeded, characterized in that a predetermined driving force profile is stored for the entire reciprocating movement of the ram, the actual driving force is measured during the entire reciprocating movement of the ram, and the measured driving force is continuously compared with the predetermined driving force, and the tamping machine is switched off when the two forces differ from each other beyond a predetermined tolerance zone.

[0004] From Heidenhain: "Dynamic Efficiency - efficient and reliable machining" is a previously known method for adaptive feed control of a milling spindle, which is used in the machining of difficult-to-machine metals and alloys used in aerospace engineering. If an exceedance of the permissible maximum power of the milling spindle is detected, the feed of the milling spindle is reduced to protect the machine mechanics.

[0005] To avoid unplanned downtimes, for example, it is well known that preventive maintenance measures should be carried out according to a defined plan. Even with consistent implementation of preventive maintenance measures, brush manufacturing machines can unexpectedly develop conditions that could impair proper operation. Identifying the causes and correcting such conditions often requires a considerable amount of time, during which the affected brush manufacturing machines are unavailable for production.

[0006] The object of the invention is therefore to provide a method and a brush manufacturing machine of the type mentioned at the outset, with which the disadvantages outlined above can be avoided and brush manufacturing can be made more efficient.

[0007] To achieve this object, the method of the type mentioned above proposes the means and features of the independent claim directed to such a method. Thus, in particular, to achieve this object, a method for producing brushes using a brush manufacturing machine is proposed, in which a control unit of the brush manufacturing machine autonomously triggers a reaction depending on an input variable in order to at least indirectly control the brush manufacturing machine to a defined target state.

[0008] The input variable considered by the control unit of the brush production machine can represent the previously outlined undesired states. As soon as the control unit detects a need for action based on the input variable, it autonomously triggers a targeted response to return the brush production machine to the defined target state. In this way, undesired states of the brush production machine can be detected early and, above all, autonomously, and appropriate responses can be autonomously defined and triggered by the brush production machine to correct or avoid the undesired state and return the brush production machine to the defined target state. In this way, brush production can be carried out more efficiently than before. Furthermore, it is possible to reduce or even completely avoid unplanned downtimes or failures of the brush production machine.

[0009] It can be particularly advantageous if a variable autonomously defined or generated by the brush manufacturing machine is used as the input variable. The autonomously defined variable can, for example, be generated by machine learning from the brush manufacturing machine and / or from the aforementioned control unit of the brush manufacturing machine.

[0010] Furthermore, it is possible to use an actual value of a process parameter of the brush manufacturing machine and / or a variable, which can in particular be a physical variable, as the input variable. The actual value of the process parameter and / or the variable can be determined, for example, using at least one sensor of the brush manufacturing machine. The brush manufacturing machine can thus be able to autonomously monitor a process parameter of the brush manufacturing machine of interest and / or a variable of interest, in particular a physical variable, and, if necessary, to initiate necessary steps just as autonomously if the process parameter of interest and / or the variable deviates from a defined tolerance range, which, without reaction, could lead to an impairment of brush production or to a failure of the brush manufacturing machine.

[0011] The input variable can be stored in a memory that is at least temporarily connected to the control unit, in particular to the brush manufacturing machine. The control unit of the brush manufacturing machine can access the memory to read the input variable and perform the control. The brush manufacturing machine, in particular the control unit, can store an input variable that is defined and / or determined by the brush manufacturing machine itself in the aforementioned memory.

[0012] The control unit of the brush manufacturing machine can further autonomously actuate at least one actuator of the brush manufacturing machine in response to the input variable, thereby controlling the brush manufacturing machine to the defined target state. This creates a method that allows the brush manufacturing machine to react largely or even completely autonomously to a determined actual value and / or an input variable. Thus, the brush manufacturing machine operating according to the method can operate largely without human supervision, thus reducing or preventing errors, malfunctions, failure risks, and the like that can be detected early.

[0013] Furthermore, it may be expedient for the brush manufacturing machine, in particular the control unit of the brush manufacturing machine, to autonomously define the target state to which the brush manufacturing machine regulates itself. This can be done, for example, based on the input variable, a predefined production program, and / or a specification transmitted to the brush manufacturing machine, in particular the control unit of the brush manufacturing machine.

[0014] It can be particularly useful if the brush manufacturing machine, in particular the control unit of the brush manufacturing machine, learns mechanically from previously performed controls to execute the reactions in an optimized manner. An optimally executed reaction can, for example, consist of the optimized actuation of an actuator of the brush manufacturing machine, in particular the one already mentioned, in order to reach the target state as quickly as possible. The machine learning can take place taking into account previously performed control processes. For this purpose, it can be advantageous if the brush manufacturing machine, in particular the control unit of the brush manufacturing machine, records performed controls / control processes and stores them in a memory, for example the one already mentioned.Based on these control processes carried out in the past, the brush manufacturing machine, especially the control unit, can learn autonomously and machine-based and adapt its behavior to new circumstances more quickly.

[0015] According to the invention, the degree of wear of a wearing part of the brush manufacturing machine is used as the input variable for the method. It can be advantageous to determine the degree of wear using at least one sensor. This at least one sensor of the brush manufacturing machine can be connected to the aforementioned control unit of the brush manufacturing machine via signal technology. For this purpose, corresponding signal connections can be present between the control unit and the at least one sensor and between the control unit and the at least one actuator. In this way, it is possible to transmit a sensor signal from the sensor to the control unit of the brush manufacturing machine. Based on the sensor signal, the control unit can then generate a control signal by which the actuator is actuated in order to bring the brush manufacturing machine into the desired state.

[0016] However, it is also possible to use as an input variable a quantity that represents the stock of production material available for production at the brush manufacturing machine. The stock of production material can be determined at least indirectly using at least one sensor on the brush manufacturing machine.

[0017] According to the invention, the drive power of the brush manufacturing machine, in particular of at least one drive of the brush manufacturing machine, is set to a defined value as a reaction, preferably with the aid of an actuator. This occurs when the input variable or a value derived therefrom has reached a defined limit. In this case, it can be provided that the drive power of the brush manufacturing machine is reduced with the aid of the actuator to a value of 90% or even 80% of the output power of the brush manufacturing machine. Of course, the drive whose power is to be temporarily reduced can also be used as the actuator and controlled directly by the control unit.

[0018] The wear level of a monitored wear part is used as an input variable. As soon as the wear level of the monitored wear part reaches a limit, the drive power of the brush manufacturing machine or a drive of the brush manufacturing machine can be reduced, for example, for safety reasons.

[0019] In this way, the service life of the wearing part of the brush manufacturing machine can be extended, if necessary, by reducing the power at which the brush manufacturing machine is operated. In this way, a wear-related failure of the brush manufacturing machine can be delayed by reducing the drive power of the brush manufacturing machine until, for example, either a replacement part for the wear part at risk of wear is available for replacement, or a production-related downtime or break is already pending, during which the wearing part can be replaced and / or the brush manufacturing machine can be repaired without an unplanned interruption to production.

[0020] Furthermore, the wear level trend of a monitored wear part of the brush manufacturing machine can be compared with at least one wear level trend recorded in the past. The comparison of the wear level trends can preferably be performed using the aforementioned control unit of the brush manufacturing machine. From the comparison of the wear level trends, conclusions can be drawn about unusual wear events. This enables an early and preventative response to the current situation. This can prevent damage to the brush manufacturing machine, the production of rejects, and / or potentially dangerous situations.Furthermore, the brush manufacturing machine can perform a self-diagnosis based on an unusual wear level of at least one monitored wear part and regulate itself back to a proper state, which may correspond to the target state, by adjusting at least one process parameter. This can preferably be done entirely without human intervention. In this context, it can be advantageous if the process parameter is adjusted using an actuator, for example the one mentioned above, that can be controlled by the control unit.

[0021] At this point it should be mentioned that process parameters also include machine parameters, the change of which can lead to a change in the behavior of the brush manufacturing machine.

[0022] In this context, it can be particularly advantageous to trigger a reaction using the control unit if the current wear level development deviates by a defined degree from the recorded wear level development, which serves as a reference. As a reaction, for example, a message regarding the wear level developments can be issued. As a reaction, a replacement part for the monitored wear part can be requested independently by the brush manufacturing machine and / or by a PPS (production planning and control system) system connected to the brush manufacturing machine. Furthermore, it is possible to autonomously perform self-diagnosis and / or error analysis as a reaction to identify necessary measures that should be taken to restore the brush manufacturing machine to its proper state.

[0023] As already mentioned, the brush manufacturing machine can, in particular with the aid of its control unit, regulate itself back to a proper state / target state. It does this by specifically changing at least one process parameter, in particular by activating at least one actuator of the brush manufacturing machine, tracking the change and its effect using at least one sensor, for example, the one already mentioned, and, if necessary, making further adjustments to at least one process parameter of the brush manufacturing machine. This continues until it has returned to its proper state and / or the defined target state.

[0024] The following are embodiments of the method, which particularly concern the previously mentioned determination of the degree of wear of a wearing part and possible variants thereof.

[0025] According to one example, the degree of wear of a bundle separator of the brush manufacturing machine is determined at least indirectly based on the quality of bristle bundles separated by the bundle separator, a measurement of the mechanical resistance when moving the bundle separator, by means of at least one sensor and / or by means of rotational movement measurement.

[0026] The quality of the separated bristle bundles can preferably be determined using a sensor, in particular a camera and / or an optical measuring arrangement. If increased wear of the bundle separator is detected, the frequency with which the bundle separator moves past a bristle supply to remove bristle bundles from the bristle supply can be reduced with the help of a corresponding actuator on the brush manufacturing machine. In this way, the bundle separator can be used for longer before it actually fails due to wear. The time gained can, for example, be used to procure a replacement part for the bundle separator. The actuator controlled by the control unit here can be a drive, in particular a pivoting drive, of the bundle separator. The bristle supply can be kept in a material box on the brush manufacturing machine.

[0027] According to one example, the degree of wear of at least one electric drive of the brush manufacturing machine is determined at least indirectly based on an operating temperature of the drive determined with the aid of a temperature sensor.

[0028] A temperature sensor can be used as a sensor for this purpose. If a critical level of wear is detected on the monitored drive, the drive power of the drive at risk of wear can be reduced using the control unit of the brush manufacturing machine to delay the expected failure and extend the drive's service life accordingly. The drive can serve as a controlled actuator in this process.

[0029] According to one example, it can further be provided that the pressure in a material box of the brush manufacturing machine, which is generated by bristle material and / or a material pusher that presses on the bristle material, is detected. For this purpose, the brush manufacturing machine can have at least one corresponding sensor. If the at least one sensor detects an excessively low pressure, the control unit of the brush manufacturing machine can cause the material pusher, acting as an actuator, to generate a higher pressure in the material box of the brush manufacturing machine. This ensures that the material pressure required for proper removal of bristle bundles from the material box of the brush manufacturing machine using a bundle separator is present in the material box.The brush manufacturing machine operating according to the process can autonomously adjust the material pressure in the material box using its control unit. Intervention by an operator of the brush manufacturing machine is not required. Furthermore, it is possible to count the number of bristles removed from the material box using an appropriate sensor, in particular a suitable camera. The number of bristles removed can be used to indirectly determine the material pressure in the material box. If the control unit detects that too few bristles have been removed, it can control the material pusher and increase the pressure in the material box via the material pusher.

[0030] According to one example, the degree of wear of at least one ram of the brush manufacturing machine is determined based on the impact force with which the ram is actuated. A force sensor can be used as a sensor for this purpose. If increased wear of the ram is measured using the sensor, the control unit of the brush manufacturing machine can reduce the frequency with which the ram is actuated in order to extend the service life of the ram until a replacement part for the ram is available.

[0031] According to one example, the degree of wear of at least one cutting device of the brush manufacturing machine is determined based on current consumption, vibration measurement, cutting time, blade temperature, and / or cutting force, preferably determined / performed with a corresponding sensor. If increased wear of the cutting device is detected, the brush manufacturing machine can, in particular by means of its control unit, reduce the number of cutting operations per unit of time in order to extend the expected service life of the cutting device. A drive of the cutting device, which can be directly controlled by the control unit, can serve as the actuator.

[0032] According to one example, the degree of wear of at least one intake line of the brush manufacturing machine for bristle filaments is determined, in particular by volume flow and / or differential pressure measurement. A pressure sensor and / or flow sensor, for example, can be used as a sensor for this purpose. The degree of wear of an intake line of the brush manufacturing machine can be caused, for example, by contamination of the intake line. If the brush manufacturing machine detects increased wear of the intake line, it can activate a cleaning device of the brush manufacturing machine, which then functions as an actuator, to clean the intake line. In the simplest case, the cleaning device can be or comprise a blower that blows a pressure surge through the intake line for cleaning purposes.

[0033] In one embodiment of the method according to the invention, the degree of wear of at least one grinding device of the brush manufacturing machine is determined, in particular by camera monitoring of a grinding tool and / or a product processed with the aid of the grinding device, based on current consumption, particle measurement, and / or dirt formation during operation of the grinding device. For this purpose, a corresponding particle sensor and / or flow sensor can be used as a sensor. A drive of the grinding device, which can be directly controlled by the control unit, can serve as an actuator.If it is foreseeable that the grinding device will fail in the foreseeable future due to increasing wear, the brush manufacturing machine, in particular the control unit of the brush manufacturing machine, can control the drive of the grinding device as an actuator in such a way that the grinding device operates at a lower power and therefore has an extended expected service life. This can delay the impending failure and gain time to procure a replacement part.

[0034] In one embodiment of the method according to the invention, the degree of wear of at least one milling cutter of the brush manufacturing machine is determined, in particular by camera control of the milling cutter and / or of an end product machined by the milling cutter, and / or based on current consumption during operation of the milling cutter. For this purpose, an optical sensor and / or a camera, for example, can be used as a sensor. A drive of the milling cutter can be used as an actuator, which the brush manufacturing machine, in particular the control unit of the brush manufacturing machine, controls in response to the degree of wear of the milling cutter. If necessary, the drive power of the drive can also be reduced here with the help of the control unit in order to extend the expected service life of the milling cutter.

[0035] In a further embodiment of the method, in particular comprising the features of one of the previous embodiments, it is provided that the degree of wear, in particular a breakage, of a pusher tongue of the brush manufacturing machine is determined, in particular based on a pusher pressure monitored by a corresponding sensor during operation of the pusher tongue, a pressure relief valve and / or a force measuring device. For this purpose, a corresponding pressure or force sensor can be used as the sensor. A pusher drive of the pusher tongue can serve as the actuator. If, for example, a breakage of the pusher tongue is at least indirectly detected, the control unit can deactivate the pusher drive of the pusher tongue in order to prevent further damage.

[0036] In a further embodiment of the method, it is provided that at least one physical property of the environment in which the method is carried out is taken into account as an input variable by the control unit of the brush manufacturing machine. Specifically, for example, air humidity and / or temperature in the environment of the brush manufacturing machine can be recorded by at least one corresponding sensor of the brush manufacturing machine and taken into account during the processing of bristle material. If the air humidity and / or temperature falls outside a tolerance range, the brush manufacturing machine, in particular the control unit, can control a heating and / or cooling and / or air conditioning device of the brush manufacturing machine as an actuator in such a way that the air humidity and / or temperature that is / are measurable in the area of ​​the brush manufacturing machine is / are regulated back into the tolerance range.It has been established that a specific humidity and / or temperature can be closely related to the quality of the end products produced on the brush manufacturing machine. There is also a relationship between machine availability and the temperature / humidity in which the brush manufacturing machine is operated. Thus, in this case, too, the brush manufacturing machine can autonomously influence its environment, taking into account a physical input variable that, if outside the tolerance range, can negatively impact machine availability and / or production quality, and use the control unit to return the brush manufacturing machine to a desired target state.

[0037] In a further embodiment of the method, a temperature and / or a specific physical and / or chemical parameter of extracted vapors during filament welding are taken into account as input variables by the brush manufacturing machine, in particular by its control unit, to adjust melting temperatures. The input variable used can be determined here by a suitable sensor of the brush manufacturing machine. A heating device of the brush manufacturing machine, with which the bristle filaments are heated for filament welding, can serve as the actuator controlled by the control unit. If an injection molding step is also used in the method, an injection pressure during injection molding can be taken into account as input variable by the brush manufacturing machine, in particular by its control unit. The injection pressure can be determined using a corresponding sensor of the brush manufacturing machine.An injection molding machine on the brush manufacturing machine can be used as a controlled actuator that can be influenced using the brush manufacturing machine's control unit. If it is determined that the injection pressure is too low, the brush manufacturing machine adjusts the injection pressure accordingly. To do this, the control unit can transmit a corresponding control or regulation signal to the injection molding machine.

[0038] In a further embodiment of the method, the degree of wear of at least one insertion servomotor of the brush manufacturing machine is determined, in particular based on temperature measurement, resistance monitoring, vibration measurement, speed monitoring, torque measurement, and counting the windings generated by the insertion servomotor. For this purpose, a suitable resistance sensor, temperature sensor, speed sensor, vibration sensor, and / or optical sensor and / or a camera can be used as a sensor. The insertion servomotor can be controlled by the control unit as an actuator in this control loop.

[0039] In a further embodiment of the method, the degree of wear of at least one push rod of the brush manufacturing machine is determined using a sensor, in particular a pressure sensor, a pressure relief valve and / or a force sensor. For this purpose, a corresponding pressure sensor and / or a force sensor can be used as the sensor. The pressure determined by the sensor or the force determined by the sensor can serve as the input variable and be taken into account by the brush manufacturing machine, in particular its control unit. A push rod drive of the push rod can be controlled as the actuator. In response to detected, critical wear, the push rod drive can be controlled accordingly by the control unit in order to extend the service life of the push rod until a replacement part for the push rod is available.

[0040] In one embodiment of the method according to the invention, the degree of wear of at least one drill bit of the brush manufacturing machine is determined, in particular based on a drill feed measurement, a torque recording on a drill chuck of the drill bit, and / or based on a rotational speed of the drill bit. A determined torque and / or a rotational speed of the drill bit can serve as an input variable. For example, a rotational speed sensor, a torque sensor, a force sensor, and / or a displacement sensor can be used as a sensor. A drive of the drill bit can serve as a possible actuator in this control loop, which in turn is controlled accordingly to bring the brush manufacturing machine into the desired target state.

[0041] In a further embodiment of the method, the degree of wear of at least one pin pack of the brush manufacturing machine is determined, preferably based on particle development during use of the pin pack with the aid of a camera and / or based on an occurring press-in pressure during use of the pin pack. For this purpose, a corresponding optical sensor and / or a pressure or force sensor and / or a camera can be used as a sensor for determining an input variable. A drive of the pin pack can serve as a possible actuator in this control loop, which in turn is controlled accordingly to bring the brush manufacturing machine into the desired target state.

[0042] In a further embodiment of the method, the degree of wear of at least one, in particular variable, circular arc notch of the brush manufacturing machine is determined, in particular indirectly by counting bristle filaments of a bristle bundle selected from a supply of loose bristle filaments using the, in particular variable, circular arc notch. For this purpose, an appropriate optical sensor and / or a camera, for example, can be used as a sensor to determine an input variable for the control. A servo drive of the variable circular arc notch can be controlled as a possible actuator in this control loop. In this example, a number of bristle filaments in a bristle bundle can be used as an input variable by the control unit for the control.

[0043] In a further embodiment of the method, the degree of wear of a wire draw-off device of the brush manufacturing machine is determined, in particular by preferably visually inspecting a wire drawn by the wire draw-off device. For this purpose, a corresponding optical sensor and / or a camera, for example, can be used as a sensor for determining an input variable. A drive of the wire draw-off device can be controlled as a possible actuator in this control loop, for example.

[0044] In a further embodiment of the method, the degree of wear of at least one wire-cutting device of the brush manufacturing machine is determined, in particular based on the current consumption during operation of the wire-cutting device, a vibration measurement, a feed-time diagram, and / or a cutting time. For this purpose, a vibration sensor, for example, can be used as a sensor to determine an input variable for the control system. A drive of the wire-cutting device can be controlled as a possible actuator in this control loop, for example.

[0045] In a further embodiment of the method, the degree of wear of at least one filament cutting device of the brush manufacturing machine is determined, in particular based on current consumption and / or vibration measurement during operation of the filament cutting device. For this purpose, a vibration sensor or an ammeter, for example, can be used as a sensor for determining an input variable. A drive of the filament cutting device can be controlled, for example, as a possible actuator in this control loop.

[0046] In a further embodiment of the method, the degree of wear of at least one stuffing tool of the brush manufacturing machine is determined, in particular by preferably optically inspecting the bristle bundles stuffed with the stuffing tool. For this purpose, a corresponding optical sensor and / or a camera, for example, can be used as a sensor for determining an input variable. A drive of the stuffing tool, for example, can be controlled as a possible actuator in this control loop.

[0047] In a further embodiment of the method, the degree of wear of at least one wire feed device of the brush manufacturing machine is determined. For this purpose, a corresponding optical sensor and / or a camera and / or a rotary encoder can be used as a sensor for determining an input variable. A drive of the wire feed device can be controlled as a possible actuator in this control loop, for example.

[0048] In a further embodiment of the method, the degree of wear of at least one clamping insert of the brush manufacturing machine for a wire to be twisted in is determined, preferably by means of voltage measurement and / or vibration measurement and / or temperature measurement on a linear motor. For this purpose, a corresponding optical sensor, a temperature sensor, a measuring circuit, a voltage measuring device, and / or a camera can be used as a sensor for determining an input variable. A drive of the clamping insert can be controlled, for example, as an actuator in this control loop.

[0049] In a further embodiment of the method, the degree of wear of a bending device of the brush manufacturing machine for bending a wire handle, for example, of a twisted-in brush, is determined, in particular by measuring the current consumption of a servo motor and / or by means of a wire feed measurement. For this purpose, an optical sensor, a temperature sensor, a measuring circuit, a voltmeter, and / or a camera can be used as a sensor for determining an input variable. A drive of the bending device can be controlled, for example, as an actuator in this control loop.

[0050] In a further embodiment of the method, the degree of wear of a wire stretching device of the brush manufacturing machine is determined, in particular by measuring the current consumption during operation of the wire stretching device and / or based on a displacement measurement, a force measurement, particularly preferably based on a tensile force measurement. For this purpose, a corresponding optical sensor, a temperature sensor, a measuring circuit, a displacement sensor, an ammeter, and / or a camera can be used as a sensor for determining an input variable. A drive of the wire stretching device can be controlled, for example, as a possible actuator in this control loop.

[0051] In a further embodiment of the method, the degree of wear of at least one puck handling hose of the brush manufacturing machine is determined, in particular by differential pressure measurement, vacuum measurement, and / or volume flow measurement. For this purpose, a corresponding pressure sensor and / or volume flow sensor and / or a camera can be used as a sensor for determining an input variable for the control. A suction device of the brush manufacturing machine can be controlled, for example, as a possible actuator in this control loop.

[0052] In a further embodiment of the method, the degree of wear of a wire cutting device, in particular for a flat wire for producing bundle anchors and / or for a round wire for producing loops, is determined, in particular by measuring a cutting force and / or by measuring or determining a geometry of the cut wire. For this purpose, an optical sensor, a force or pressure sensor, and / or a camera can be used as a sensor for determining an input variable. A drive of the wire cutting device can be controlled, for example, as a possible actuator in this control loop.

[0053] Furthermore, the stock of production material available at the at least one brush manufacturing machine can be monitored at least indirectly with the aid of a sensor, in particular with the aid of the sensor already mentioned, and taken into account as an input variable. The sensor can be configured to determine an input variable, which can also be referred to as a parameter, that represents the stock of production material and thus allows at least indirectly inferences to be drawn about the current stock.

[0054] Further embodiments of the aforementioned method are listed below, which primarily deal with variants of the previously mentioned inventory monitoring: In a further embodiment of the method, the features of one of the previous embodiments are provided, wherein the input variable is the stock of bristle material in a material box of the brush manufacturing machine using a corresponding sensor, in particular using a pressure sensor, in the material box. In response to a declining stock, the brush manufacturing machine can trigger an autonomous reorder of bristle material, in particular via its control unit. For this purpose, the control unit can, for example, issue or transmit a corresponding order message to or via a PPS system.

[0055] In a further embodiment of the method, the stock of bristle material contained in a filament strand for the production of brushes is determined and taken into account as an input variable, in particular by measuring the filament strand length using at least one corresponding sensor or displacement sensor. Here, too, a drop in the stock below a critical value can cause the control unit of the brush production machine to autonomously order a supply of required material and / or reduce a production rate. The aim of this is to be able to produce with the remaining stock until a planned downtime of the brush production machine occurs again and / or a supply of material has been delivered to the brush production machine. In this way, an unplanned downtime in production can be prevented.

[0056] To achieve this object, a brush manufacturing machine having the means and features of the independent claim directed to a brush manufacturing machine is also proposed. In particular, to achieve this object, a brush manufacturing machine is proposed that is configured to carry out the method described in detail above and claimed in the corresponding claims.

[0057] For this purpose, the brush manufacturing machine can have a control unit, at least one sensor and / or at least one actuator. The sensor and the actuator can be connected to the control unit of the brush manufacturing machine via signal connections. In this way, data, information, measured values ​​or the like detected by the sensor can be made available to the control unit for control purposes. Via the signal connection between the control unit and the actuator, the control unit can transmit control and / or regulation signals to the at least one actuator of the brush manufacturing machine. The sensor is preferably designed to determine an actual value of at least one process parameter of the brush manufacturing machine that can be influenced by the actuator as an input variable for the control unit.The sensor can be configured to determine an actual value of a quantity of interest, in particular a physical quantity, as an input variable that can be taken into account by the control unit. The control unit can be configured to operate the actuator autonomously. This is done with the aim of controlling the brush manufacturing machine to a defined target state.

[0058] Furthermore, the brush manufacturing machine, in particular a control unit of the brush manufacturing machine, can be configured to autonomously generate an input variable. Particularly in such a brush manufacturing machine that is equipped with artificial intelligence and / or configured for machine learning, the brush manufacturing machine can thus itself define an input variable that can be made available to the control unit of the brush manufacturing machine for the desired autonomous control of the brush manufacturing machine. This makes it possible to create a brush manufacturing machine that is self-learning and can trigger defined reactions based on experience in order to return itself, autonomously and as quickly and efficiently as possible, to the defined target state when deviations from a defined target state of the brush manufacturing machine are detected.In this way, defective production, rejects and the like can be avoided and the production of brushes can be made more efficient.

[0059] An input variable considered by the brush manufacturing machine can be the degree of wear of a wear part. Furthermore, the brush manufacturing machine can have at least one sensor, for example the one already mentioned, which is configured to determine the degree of wear of a wear part of the brush manufacturing machine. Thus, a brush manufacturing machine is created that is capable of autonomously triggering reactions, taking into account the degree of wear of at least one wear part. This can be done by actuating the actuator of the brush manufacturing machine mentioned above.The aim of the autonomously triggered reactions can, for example, be to extend the service life of the brush manufacturing machine in such a way that the brush manufacturing machine can be operated with, for example, reduced power until either a planned maintenance interval is due and / or a spare part for the monitored wear part is available for replacement.

[0060] It may also be advantageous if the brush manufacturing machine has at least one actuator, for example the one already mentioned above, by means of which the control unit is configured to change a process parameter and / or a setting of the brush manufacturing machine in order to control the brush manufacturing machine to the desired state.

[0061] In one embodiment of the brush manufacturing machine, the control unit can be configured, in particular by means of an actuator or the actuator, to change, in particular to reduce, a drive power of the brush manufacturing machine. The aim of this is to control the brush manufacturing machine to the target state. It should be noted here that the target state can naturally vary depending on the respective situation in which the brush manufacturing machine finds itself. For example, if excessive wear of a safety-relevant wearing part is detected by the brush manufacturing machine, it may be advantageous or necessary, for safety reasons alone, to reduce the drive power of the brush manufacturing machine, e.g., to 90% or 80% of the output power of the brush manufacturing machine. In this way, damage to the brush manufacturing machine due to a failure of the wearing part threatened by wear can be avoided.In addition, the service life of the brush production machine, especially of the wearing part, can be extended if necessary by reducing the drive power. This can prevent unplanned production downtime. This is particularly relevant in a linked production of brushes, in which several brush production machines are linked together for production purposes. In this case, the overall availability of the linked production facility can be determined, for example, by multiplying the technical availability of the linked individual machines. Therefore, optimizing the individual availability is crucial for achieving high overall availability.

[0062] The brush manufacturing machine can have as at least one sensor, for example, a vibration sensor, a force sensor, a pressure sensor, a volume flow sensor, a temperature sensor, an optical sensor, a measuring circuit and / or a camera.

[0063] All data, values, states and / or variables that can be determined with the at least one sensor can be used by the brush manufacturing machine and also within the framework of the process as input variables and can be taken into account by the control unit.

[0064] Below, embodiments of the brush manufacturing machine described above are explained in more detail, primarily dealing with variants of the at least one sensor for determining an input variable representing the degree of wear of a wear part of the brush manufacturing machine. Naturally, all of the specific features mentioned and explained in connection with the method described in detail above are suitable for forming further embodiments of the brush manufacturing machine in combination with the features of the brush manufacturing machine set forth in the claims.

[0065] According to one example, the at least one sensor is configured to determine the degree of wear of at least one bundle separator of the brush manufacturing machine. The degree of wear serves as an input variable. A camera, for example, can be used as a sensor, with which the quality of the bristle bundles separated by the bundle separator can be monitored, preferably continuously.

[0066] According to one example, the at least one sensor is a temperature sensor for measuring the temperature of at least one electric drive of the brush manufacturing machine.

[0067] According to one example, the at least one sensor is a force sensor for monitoring a cutting force of a cutting device and / or a sensor and / or a camera for monitoring a geometry of a wire cut with the cutting device.

[0068] According to one example, the at least one sensor is a force sensor for monitoring the impact force of a ram of the brush manufacturing machine. This is done with the aim of preferably continuously monitoring the degree of wear of the ram. There may be a correlation between the increasing degree of wear of the ram and the increasing impact force.

[0069] According to one example, the at least one sensor is a sensor for at least indirectly determining the degree of wear of a filament cutting device of the brush manufacturing machine. A force and / or pressure sensor, for example, can function as a sensor for determining an input variable.

[0070] According to one example, the at least one sensor is a sensor for determining a degree of wear of at least one suction hose of the brush manufacturing machine for bristle filaments, in particular a volume flow sensor and / or a pressure sensor.

[0071] In an embodiment of the brush manufacturing machine according to the invention, in particular comprising the features of one of the previous embodiments, it is provided that the at least one sensor is a sensor, in particular a camera and / or an optical sensor, for at least indirectly determining the degree of wear of a grinding device of the brush manufacturing machine.

[0072] In an embodiment of the brush manufacturing machine according to the invention, in particular comprising the features of one of the previous embodiments, it is provided that the at least one sensor is a sensor for at least indirectly determining the degree of wear of a milling cutter of the brush manufacturing machine, in particular a camera and / or a sensor for determining a current consumption during operation of the milling cutter, for example an ammeter or a current measuring circuit.

[0073] According to one example, the at least one sensor is a sensor for at least indirectly determining the degree of wear of a screw-in servo motor, in particular a temperature sensor, a resistance sensor, a speed sensor, a vibration sensor and / or a torque sensor and / or a device for counting turns generated when a wire is screwed in.

[0074] According to one example, the at least one sensor is a sensor for at least indirectly determining the degree of wear of at least one pusher tongue of the brush manufacturing machine, in particular a pressure sensor and / or a force sensor and / or a pressure relief valve.

[0075] In an embodiment of the brush manufacturing machine according to the invention, in particular comprising the features of one of the previous embodiments, it is provided that the at least one sensor is a sensor for at least indirectly determining the degree of wear of a drill bit of the brush manufacturing machine, a sensor, in particular a sensor for measuring a drill feed, a torque sensor on a drill chuck of the drill bit and / or a speed sensor.

[0076] According to one example, the at least one sensor is a sensor for at least indirectly determining the degree of wear of at least one pin pack of the brush manufacturing machine, in particular a camera, a pressure sensor and / or an optical sensor, preferably for determining particle development when using the pin pack.

[0077] According to one example, the at least one sensor is a sensor for at least indirectly determining the degree of wear of a, in particular variable, circular arc notch of a bundle separating device of the brush manufacturing machine, in particular with which a counting of bristle filaments combined into bundles with the aid of the circular arc notch is possible.

[0078] According to one example, the at least one sensor is a sensor for at least indirectly determining the degree of wear of a wire pre-drawing device of the brush manufacturing machine, in particular with which a wire drawn with the wire pre-drawing device can be checked with regard to its thickness, width, hardness, and corrugation.

[0079] According to one example, the at least one sensor is a sensor for at least indirectly determining the degree of wear of a wire cutting device of the brush manufacturing machine, in particular with which a vibration measurement can be carried out, a current consumption during operation of the wire cutting device can be measured and / or a feed-time diagram and / or a cutting time can be determined.

[0080] According to one example, the at least one sensor is a sensor for at least indirectly determining the degree of wear of a filament cutting device of the brush manufacturing machine, in particular with which a current consumption measurement and / or a vibration measurement can be carried out during operation of the filament cutting device.

[0081] According to one example, the at least one sensor is a sensor for at least indirectly determining the degree of wear of at least one stuffing tool of the brush manufacturing machine, preferably a camera with which the quality of bristle bundles stuffed using the stuffing tool can be checked.

[0082] According to one example, the at least one sensor is a sensor for determining the degree of wear of a wire feed device of the brush manufacturing machine, in particular a camera and / or a rotary encoder.

[0083] According to one example, the at least one sensor is a sensor for at least indirectly determining the degree of wear of at least one clamping insert of the brush manufacturing machine, with which a wire can be held during screwing in, in particular wherein the sensor is configured to carry out a voltage measurement on a linear motor with which the clamping insert is moved, and / or comprises or is a camera.

[0084] According to one example, the at least one sensor is a sensor for at least indirectly determining the degree of wear of a bending device of the brush manufacturing machine for bending a wire, in particular for V-bending a wire stem of a brush to be produced, in particular, which is configured to measure a current consumption at the servomotor and / or to measure a feed rate. The sensor can, for example, be a displacement sensor or comprise an ammeter and / or a camera.

[0085] According to one example, the at least one sensor is a sensor for at least indirectly determining the degree of wear of a wire stretching device of the brush manufacturing machine, in particular with which a current consumption measurement, a displacement measurement (displacement sensor) and / or a measurement of tensile forces (force and / or pressure sensor) can be measured during operation of the wire stretching device.

[0086] According to one example, the at least one sensor is a sensor for at least indirectly determining the degree of wear of at least one puck handling hose of the brush manufacturing machine, in particular a suction hose, in particular a pressure sensor and / or a volume flow sensor and / or an optical sensor, and / or a camera.

[0087] According to one example, the at least one sensor is a sensor for at least indirectly determining the degree of wear of a wire cutting device of the brush manufacturing machine, in particular for a flat wire for producing bundle anchors and / or for a round wire for producing loops, in particular a cutting force sensor, and / or for measuring a geometry of a cut wire.

[0088] The brush manufacturing machine can further be configured to monitor a stock of production material available to the brush manufacturing machine for producing brushes. For this purpose, the brush manufacturing machine can have at least one corresponding sensor, at least one corresponding measuring device, and / or at least one camera. A variable determined by the sensor that is related to the stock of production material can be taken into account by the control unit as an input variable. Furthermore, it should be noted that, in the context of the claimed technical teaching, production material is understood to mean any material that is required or used in the production of brushes for operating the brush manufacturing machine. Production material in the context of the claimed technical teaching also includes material that becomes a component of the products to be manufactured.

[0089] Embodiments of the brush manufacturing machine are described below, which relate to variants of the at least one sensor for monitoring the stock of production material: According to one example, the at least one sensor is configured to monitor the stock of bristle material in a material box of the brush manufacturing machine, in particular wherein the at least one sensor is a pressure sensor.

[0090] According to one example, the at least one sensor is configured to monitor the stock of bristle material in a filament strand that can be processed with the brush manufacturing machine, in particular wherein the sensor is configured to determine a remaining length of a filament strand.

[0091] The invention will now be described in more detail with reference to exemplary embodiments, but is not limited to these exemplary embodiments. Further exemplary embodiments result from the combination of the features of individual or multiple claims with one another and / or from the combination of individual or multiple features from the general description and / or the exemplary embodiments. In a partially highly schematic representation: Figure 1: A flowchart illustrating a first variant of the method according to the invention. Figure 2: Another flowchart illustrating a further variant of the method according to the invention. Figure 3: A schematic representation of a brush manufacturing machine configured to carry out the method. Figure 4: A control loop used in carrying out the method, comprising a control unit, a sensor, and an actuator of the brush manufacturing machine.

[0092] In the following description of various embodiments of the invention, elements that correspond in their function are given the same reference numbers even if they have a different design or shape.

[0093] All figures show at least parts of a brush manufacturing machine, designated as a whole by 1. The brush manufacturing machine 1 comprises a control unit 2, at least one sensor 3, and at least one actuator 4. The control unit 2 is configured to actuate the actuator 4 autonomously in order to control the brush manufacturing machine 1 to a defined target state. The autonomous actuation of the actuator 4 may also take into account an input variable, which can be determined, for example, using the aforementioned sensor 3. The input variable can represent certain process parameters relevant to the production of brushes and / or situation-dependent influencing factors, which are autonomously analyzed by the control unit 2 of the brush manufacturing machine 1. If the brush manufacturing machine 1, in particular its control unit 2, detects a need for action, the reaction is triggered.

[0094] Both sensor 3 and actuator 4 are connected to the control unit 2 of the brush manufacturing machine 1 via signal connections 2b. This makes it possible to transmit an input variable determined by sensor 3 to the control unit 2. After analyzing the input variable, the control unit 2 can, if a need for action has been identified, control the actuator 4 via the signal connection accordingly in order to control the brush manufacturing machine 1 to the desired target state.

[0095] Sensor 3 is configured to determine, as an input variable for the control system, an actual value of a particular physical variable and / or an actual value of a process parameter of brush manufacturing machine 1. For this purpose, input variables that are related to a process parameter of brush manufacturing machine 1, which in turn can be influenced by the at least one actuator 4, are particularly suitable. Various variables and parameters that can be used, at least indirectly, as input variables are explained in detail in the general part of the description.

[0096] The brush manufacturing machine 1 further comprises a memory 2a, which the control unit 2 of the brush manufacturing machine 1 has access to. This memory 2a can store predefined input variables for the control system, both determined by the brush manufacturing machine 1 itself and defined by the brush manufacturing machine 1 or its control unit 2. The control unit 2 can read the input variables from the memory 2a via its access to the memory 2a and use them for analysis and as a starting point for autonomous control.

[0097] The brush manufacturing machine 1 or its control unit 2 are further configured to autonomously generate an input variable for controlling the brush manufacturing machine 1 and its actuators 4. Furthermore, the brush manufacturing machine 1 is configured for machine learning via its control unit 2. Based on past control processes, the brush manufacturing machine 1 can thus independently generate optimized response patterns to optimize the control of the brush manufacturing machine 1 to the desired state. The input variable considered by the brush manufacturing machine 1 can, for example, be the degree of wear of a wearing part 5, 6 of the brush manufacturing machine 1.

[0098] Different wearing parts 5, the degree of wear of which can be taken into account by the brush manufacturing machine 1 and its control unit 2 when carrying out the method, are explained in detail in the general part of the description. The sensor(s) 3 of the brush manufacturing machine 1 are then configured accordingly to determine the degree of wear of the monitored wearing part 5. This can be done directly by observing and / or measuring the respective wearing part 5 or directly based on a variable related to the degree of wear of the wearing part 5. In this case, for example, a production result in which the observed wearing part 5 is involved can be monitored, controlled or evaluated. Based on a deteriorating result, conclusions can be drawn about the degree of wear of the wearing part 5.The result of this test can thus be taken into account as an input variable for the autonomous control of the brush manufacturing machine 1 by the control unit 2.

[0099] The previously mentioned at least one actuator 4 of the brush manufacturing machine 1 is configured to change a process parameter and / or a setting of the brush manufacturing machine 1 such that the brush manufacturing machine 1 is controlled to the desired target state. Figures 3 and 4In the embodiment of a brush manufacturing machine 1 shown, a monitored wear part 5 is a bundle remover 6 of the brush manufacturing machine 1. With the help of the bundle remover 6, bristle bundles are picked out of a material box 7 of the brush manufacturing machine 1 and transferred to a stuffing tool 8 of the brush manufacturing machine 1. With the help of the stuffing tool 8, the bristle bundles are stuffed one after the other into a brush body 9 of a brush to be manufactured. For this purpose, the brush body 9 is clamped onto a holding device 10 of the brush manufacturing machine 1.

[0100] If a sensor 3 of the brush manufacturing machine 1 detects that the bristle bundles removed by the bundle separator 6 no longer meet the required quality, this may be due to increasing wear on the bundle collector 6. If the quality of the removed bristle bundles allows continued production of brushes, the actuator 4, here a drive 11 of the bundle collector 6, can be controlled by the control unit 2 such that the drive power of the drive 11 is reduced. This may mean that the bundle collector 6 is moved at a lower speed. This leads to an increase in the cycle time or a decrease in the number of bristle bundles removed per unit of time. In this way, the expected service life of the bundle collector 6 can be extended.

[0101] Depending on the application, different sensors can be used as sensors 3. For example, it is conceivable that the brush manufacturing machine 1 has at least one sensor 3, a vibration sensor, a force sensor, a pressure sensor 12, a volume flow sensor, a temperature sensor, an optical sensor, a measuring circuit, and / or a camera 16.

[0102] Based on the Figures 3 and 4 A further control loop can be explained with reference to the embodiment of the brush manufacturing machine 1 shown. This control loop comprises, as sensors 3, several pressure sensors 12 distributed in or on the material box 7 of the brush manufacturing machine 1. These pressure sensors 12 measure the material pressure transmitted to the bristle filaments 13 located in the material box 7. The material pressure, which acts on the pressure sensors 12 of the brush manufacturing machine 1 via the bristle filaments 13, is generated by material pressure sensors 14.

[0103] The pressure values ​​determined by the pressure sensors 12 are provided to the control unit 2 of the brush manufacturing machine 1 as an input variable. If the material pressure, which is recorded by the pressure sensors 12, falls below a critical value, the control unit 2 uses a corresponding control signal to cause the material pushers 14 to increase the pressure acting on the bristle filaments 13 in order to bring the material pressure in the material box 7 into a target range. The material pressure exerted by the material pushers 14 on the bristle filaments 13 in the material box 7 ensures that the bristle filaments 13 are pressed against the bundle remover 6. Correct material pressure in the material box 7 is important for the uniform removal of bristle bundles using the bundle remover 6.

[0104] For removing bristle bundles, the bundle remover 6 has a separation notch 15 into which the bristle filaments 12 are pressed due to the material pressure as the bundle remover 6 moves past the material box 7. If the material pressure is too low, bristle bundles are removed which contain too few bristle filaments 13. The control as to whether removed bristle bundles contain a sufficient number of bristle filaments 13 is carried out in the Figure 3The embodiment of the brush manufacturing machine 1 shown in FIG. 1 uses a sensor 3 in the form of a camera 16. The camera 16 can be used to determine the number of bristle filaments 13 gathered in a bristle bundle. The determined number of bristle filaments 13 in a bristle bundle is compared with a target value by the control unit 2 of the brush manufacturing machine 1. If this comparison reveals that too many bristle filaments 13 have been gathered in a bristle bundle, the pressure exerted by the material pushers 14 on the bristle filaments 13 in the material box 7 of the brush manufacturing machine 1 can be reduced by a corresponding control signal from the control unit 2 to the material pushers 14.If, during the inspection of the bristle bundles using the camera 16 as sensor 3, it is determined that the number of bristle filaments 13 in a stuffed bristle bundle is too low, the control unit 2 of the brush manufacturing machine 1 autonomously generates a control signal which is transmitted to the material pressers 14 and causes them to increase the material pressure on the bristle filaments 13 in the material box 7 of the brush manufacturing machine 1.

[0105] The brush manufacturing machine 1 is thus configured to carry out the method described below. The control unit 2 of the brush manufacturing machine 1 autonomously triggers a reaction depending on an input variable in order to at least indirectly control the brush manufacturing machine 1 to a defined target state. A variable autonomously defined or generated by the brush manufacturing machine 1, in particular through machine learning, can be used as the input variable. However, it is also possible to use an actual value of a physical variable as the input variable. The actual value of the physical variable is determined using at least one sensor 3, 12, 16 of the brush manufacturing machine 1. The physical variable is related to a process parameter of the brush manufacturing machine 1, which in turn can be influenced by an actuator 4, 11, 14 of the brush manufacturing machine 1.

[0106] The control unit 2 of the brush manufacturing machine 1 then actuates at least one actuator 4, 11, 14 of the brush manufacturing machine 1, taking into account the input variable, in response to a detected deviation from a target state. Through the targeted and autonomous actuation of the actuator 4, 11, 14 of the brush manufacturing machine 1, the brush manufacturing machine 1 is controlled to the defined target state.

[0107] The brush manufacturing machine 1 is configured, particularly through its control unit 2, to learn automatically from past control processes. As a result, the control unit 2 executes the reactions in a targeted and optimized manner and, for example, actuates the actuators 4, 11, 14 in an optimized manner to achieve the desired state as quickly as possible.

[0108] In one embodiment of the method, for the execution of which the brush manufacturing machine 1, at least partially illustrated in the figures, is also configured, a degree of wear of a wearing part 5, 6 of the brush manufacturing machine 1 is used as a further input variable. The degree of wear can be determined at least indirectly using at least one sensor 3, 12, 16.

[0109] In a further embodiment of the method, which the brush manufacturing machine 1 is also configured to carry out, a variable representing a stock of production material, here, for example, a stock of bristle filaments 13 in the material box 7 of the brush manufacturing machine 1, is used as the input variable. The stock can be determined at least indirectly using at least one sensor 3, 12, 16 of the brush manufacturing machine. The previously mentioned pressure sensors 12, which are distributed across the material box 7 of the brush manufacturing machine 1, can be used to monitor the stock of the material box 7.In response to a decreasing stock of bristle filaments 13 in the material box 7 of the brush manufacturing machine 1, the control unit 2 of the brush manufacturing machine 1 can autonomously reorder a supply of bristle filaments 13 and / or, if necessary, extend the cycle time and thus reduce the production rate. The goal is to avoid an unplanned downtime of the brush manufacturing machine 1 and to be able to continue production at least at a reduced production rate.

[0110] Furthermore, the brush manufacturing machine 1 can, with the aid of its control unit 2 and at least one corresponding actuator 4, 11, set a drive power of the brush manufacturing machine 1 to a defined value, for example, reduce it to a value of 90% or 80% of an output power. This is particularly true when the degree of wear of a monitored wear part 5, e.g., the bundle collector 6, has reached a defined limit. In this way, the service life of the monitored wear part 5, here the bundle collector 6, can be extended. Furthermore, further damage to the brush manufacturing machine 1 can be avoided or reduced, as can a potential risk of accident or injury for an operator of the brush manufacturing machine 1.

[0111] The brush manufacturing machine 1 is further capable of comparing the wear level of a monitored wearing part 5, 6 of the brush manufacturing machine 1 with at least one wear level development recorded in the past. The wear level development can thus function as an input variable for the control system. The comparison of the current wear level development with a wear level development stored in the control unit 2 and / or in the memory 2a connected to it is carried out with the aid of the control unit 2. The control unit 2 then triggers a targeted reaction if the current wear level development deviates from the recorded wear level development by a defined amount. In response to a deviating wear level development, a message, in particular a warning message 17, can be output to a terminal device 18 serving as actuator 4.

[0112] Furthermore, in response to such a deviating wear level development, it is possible to autonomously request a replacement part for the monitored wear part 5, 6 of the brush manufacturing machine 1 using the brush manufacturing machine 1 or a PPS system 19 connected to the brush manufacturing machine 1. Furthermore, if a critical wear level development is identified, the brush manufacturing machine 1 can autonomously perform a self-diagnosis and / or error analysis using its control unit 2 and attempt to counteract the negative wear level development by adjusting defined process parameters (see reference numeral 20).

[0113] Thus, the brush manufacturing machine 1 is configured, in particular via its control unit 2, to return itself to a proper state if it has detected an improper state. This is preferably done by the brush manufacturing machine 1 specifically changing a process parameter, in particular by actuating at least one actuator 4, 11, 14 of the brush manufacturing machine 1. The resulting changes and their effects are tracked using at least one sensor 3, 12, 16 of the brush manufacturing machine 1 and analyzed and evaluated by the control unit 2 in order to make further adjustments to at least one process parameter if necessary. This continues until the brush manufacturing machine 1 has autonomously returned to its proper target state.

[0114] Figure 1shows a flowchart of an embodiment of a method according to the invention. On the right side of Figure 1 is shown how the method according to the invention works. On the left half of Figure 1a process sequence is shown which corresponds to the current state of the art. At the start of operation of the brush manufacturing machine 1, it is in an optimal condition (100%). Over time, the condition of the brush manufacturing machine 1 deteriorates, e.g. due to wear of a wearing part 5, to 98% and finally to 80% of the initial condition. As soon as the brush manufacturing machine 1 has reached the 80% condition, it issues a warning message. This warning message can be perceived by an operator 21 of the brush manufacturing machine 1. The warning message prompts the operator 21 of the brush manufacturing machine 1 to carry out an error analysis and to return the brush manufacturing machine 1 to an improved condition of e.g. 90% by manually changing at least one process parameter of the brush manufacturing machine 1.Over possibly several iterations, the brush manufacturing machine 1 can be gradually returned to its optimal initial state with the help of the operator 21. However, this procedure requires a high level of qualification and considerable experience on the part of the operator 21. If neither of these skills is present, repairing the brush manufacturing machine 1 can take a disproportionately long time.

[0115] According to the right half of Figure 1Intervention by an operator 1 of the brush manufacturing machine 1 is not necessary. Starting from the optimal state (100%) of the brush manufacturing machine 1, its condition deteriorates as the brush manufacturing machine 1 continues to operate. Since the brush manufacturing machine 1 monitors itself using the means described in detail above, in particular using its control unit 2, it can autonomously initiate reactions and countermeasures even if its condition drops to 98% in order to specifically return to the initial state, which here is the defined target state.

[0116] To inform an operator 21, the brush manufacturing machine 1 can also output messages / warnings 17 here. It is advantageous for the brush manufacturing machine 1 to make the necessary adjustments itself, e.g., by varying at least one process parameter / machine parameter of the brush manufacturing machine 1. Using its at least one sensor 3, the brush manufacturing machine 1, in particular its control unit 2, can check the effectiveness of the changes made and, if necessary, make further adjustments.

[0117] Figure 2 shows another example of a method according to the invention. On the right side, the Figure 2 The method according to the invention is shown again, while on the left side of Figure 2 a process is depicted which corresponds to the current state of the art.

[0118] Starting from an optimal condition of 100% of the brush manufacturing machine 1, the condition of a wear part 5, a drive chain, deteriorates during operation of the brush manufacturing machine 1. In the methods known from the prior art, the brush manufacturing machine 1 continues to operate until the wear part 5 fails, i.e., in this case, the drive chain breaks. This leads to an unplanned downtime / failure of the brush manufacturing machine 1, which can cause major problems in automated production.

[0119] The brush manufacturing machine 1 does indeed issue a warning / fault message 17. However, it takes some time until the operator 21 of the brush manufacturing machine 1 finds the error and orders a replacement part for the wear part 5. If the replacement part for the wear part 5 is not in stock, it is necessary to order the replacement part for the wear part 5 from a supplier 22 of the wear part 5.

[0120] Until the replacement part for wear part 5 is delivered, a certain amount of time passes during which the brush manufacturing machine 1 cannot produce. Until the operator 21 has installed the replacement part for wear part 5, production cannot be resumed.

[0121] In comparison, the method according to the invention, which is shown on the right side of Figure 2illustrated, unplanned downtimes are completely eliminated. Although the wearing part 5, in this case the drive chain, is also affected by wear during operation of the brush manufacturing machine 1 in the method according to the invention, the wearing part 5 is continuously monitored during operation of the brush manufacturing machine using a sensor 3, in this case a camera 16. If it is determined that the degree of wear of the wearing part 5 has increased and that production at full capacity is therefore no longer possible, the brush manufacturing machine 1 issues a warning message 17. In a further step, the brush manufacturing machine 1 autonomously orders a spare part for the monitored wearing part 5 that is to be replaced soon. The operator 21 of the brush manufacturing machine 1 is in turn informed of this. This ordering process either takes place completely autonomously, or the system first waits for the order to be released by the operator 21.The order is finally transmitted to a supplier 22 for the replacement part of the wear part 5. Supplier 22 processes the order and confirms it, providing feedback on the estimated costs and an estimated delivery date.

[0122] During this time, the brush manufacturing machine 1 can initially produce at full capacity. If the degree of wear of the wearing part 5 continues to increase, the power of the brush manufacturing machine 1, in this case a drive 11 of the brush manufacturing machine 1, can be reduced, for example, to a value of 80% of the output power. In this way, the service life of the wearing part 5 can be extended until the replacement part for the wearing part 5 is delivered and can be installed.

[0123] The invention relates to improvements in the technical field of brush production. As an improvement, a brush production machine 1 is proposed, in particular, which is configured to carry out a method for producing brushes. In this case, a control unit 2 of the brush production machine 1 autonomously triggers a reaction depending on an input variable in order to at least indirectly control the brush production machine 1 to a defined target state. List of reference symbols

[0124] 1Brush manufacturing machine 2Control unit 2aMemory 2bSignal connection 3Sensor 4Actuator 5Wearing part 6Bundle remover 7Material box 8Stuffing tool 9Brush body 10Holding device 11Drive 12Pressure sensor 13Bristle filaments 14Material pusher 15Parting notch 16Camera 17Warning message 18End device 19PPS system 20Adjustment of process parameters 21Operator 22Supplier

Claims

1. Method for manufacturing brushes using a brush manufacturing machine (1), wherein a control unit (2) of the brush manufacturing machine (1) autonomously triggers a response depending on an input variable in order to control the brush manufacturing machine (1) at least indirectly to a defined target state, wherein a degree of wear of a wear part (5, 6), specifically at least one grinding device, at least one milling cutter and / or at least one drill, is used as the input variable, and wherein the drive power of the brush manufacturing machine (1) is reduced to a defined value in response if the degree of wear or a value derived therefrom has reached a defined limit value.

2. Method according to claim 1, wherein the degree of wear is determined at least indirectly by means of at least one sensor (3, 12, 16), specifically wherein the degree of wear of the grinding device is determined by camera monitoring of a grinding tool and / or a product machined by means of the grinding device, on the basis of a current consumption, a particle measurement and / or on the basis of dirt formation during operation of the grinding device, wherein the degree of wear of the milling cutter is determined by camera monitoring of the milling cutter and / or an end product machined by the milling cutter and / or on the basis of a current consumption during operation of the milling cutter, and / or wherein the degree of wear of the drill is determined by means of a drill feed measurement, a torque measurement on a drill chuck of the drill and / or by means of a rotational speed of the drill.

3. Method according to one of the preceding claims, wherein the brush manufacturing machine (1), in particular the control unit (2) of the brush manufacturing machine (1), autonomously defines the target state, in particular on the basis of the input variable, a predetermined production program and / or a predetermined value transmitted to the brush manufacturing machine (1), in particular to the control unit (2) of the brush manufacturing machine (1).

4. Method according to one of the preceding claims, wherein the brush manufacturing machine (1), in particular the control unit (2) of the brush manufacturing machine (1), learns mechanically, preferably from previously performed control processes, to perform the response in an optimized manner, in particular to actuate the actuator (4, 11, 14) in an optimized manner in response in order to achieve the defined target state.

5. Method according to one of the preceding claims, wherein in response, the drive power of the brush manufacturing machine (1), in particular at least one drive (11) of the brush manufacturing machine (1), is set to a defined value, specifically to a value of 90% or 80% of an output power, when the degree of wear or a value derived therefrom has reached a defined limit value.

6. Method according to one of the preceding claims, wherein the brush manufacturing machine (1), in particular by means of its control unit (2), automatically returns itself to the target state when an improper state has been detected, preferably by the brush manufacturing machine (1) purposefully changing at least one process parameter, in particular by actuating at least one actuator (4, 11, 14) of the brush manufacturing machine (1), monitoring the change and its effect by means of at least one sensor and, optionally, making further adjustments to at least one process parameter until the target state is reached.

7. Brush manufacturing machine (1) designed to carry out the method according to one of the preceding claims, wherein the brush manufacturing machine (1) has a control unit (2) and at least one grinding device, at least one drill and / or at least one milling cutter, wherein an input variable taken into account by the brush manufacturing machine (1) is a degree of wear of a wear part (5), specifically the grinding device, the milling cutter and / or the drill, and wherein the brush manufacturing machine has at least one sensor (3) which is designed to determine a degree of wear of the wear part (5), and wherein the control unit (2) is designed, in response, to reduce the drive power of the brush manufacturing machine (1) to a defined value when the degree of wear or a value derived therefrom reaches a defined limit value.

8. Brush manufacturing machine (1) according to claim 7, characterized in that the brush manufacturing machine (1), in particular the control unit (2) of the brush manufacturing machine (1), is designed for machine learning.

9. Brush manufacturing machine (1) according to one of claims 7 or 8, wherein the brush manufacturing machine (1) has as at least one sensor (3) a vibration sensor, a force sensor, a pressure sensor (12), a volume flow sensor, a temperature sensor, an optical sensor, a measuring circuit, a resistance sensor, a speed sensor, a particle sensor, a flow sensor and / or a camera (16).