Brush manufacturing equipment

Abstract

An embodiment of the present disclosure provides a brush manufacturing apparatus (100) comprising a rotary conveying mechanism (160), a bristle carrier loading station (110), one or more bristle dispensing stations (120a-120d), an ultrasonic fusing station (130), a heating station (140), a removal station (150), and a logic controller system, the one or more bristle dispensing stations (120a-120d) comprising a bristle supply mechanism (200), a bristle bundle picker (240), and a bristle implantation feeder (250) for implanting high density, short length bristle bundles onto a bristle carrier (170) having fine pitch openings, the logic controller system providing programmed commands, controlling machine sequences, and monitoring feedback of operating conditions at each station through a network of sensors and actuators.

Description

【Technical Field】 【0001】 The present invention generally relates to brush manufacturing. 【Background Art】 【0002】 This section is only intended to provide background information related to the similar fields of the present invention, does not approve the prior art, and can only be used to deepen the understanding of the present invention. 【0003】 Currently, depending on specific cleaning purposes, it is always necessary to manufacture unique types of brushes. These brushes need to be of various shapes and sizes according to their specific uses. For the delicate cleaning of filter meshes, it is necessary to manufacture modular brushes, and the filter meshes include those made of metal, plastic, or fabric. 【0004】 Due to the unique shapes of these filters, it is necessary to modularize the brushes and combine them to form one brush product. The dimensions of each brush module are usually less than 20 mm in length and width. The shape of the brush module is either square or rectangular. The module is curved to effectively contact the filter surface. 【0005】 To effectively clean the gaps of the filter mesh, it is necessary to embed bristle tufts in a matrix, and different arrays are required for different product groups. For example, there was a product specification of 5 rows and 4 columns with a pitch between bristle tufts of less than 5 mm. 【0006】 Based on the above requirements, it was necessary to manufacture the brush products in an economically efficient and feasible manner. The manufacturing process had to achieve a daily production quota for brush modules while ensuring short turnaround times, minimizing in-process waste of raw materials, and reducing defective products. However, no commercially available equipment existed that could manufacture this particular group of brush products. 【0007】 Therefore, in light of the above discussion, it was necessary to overcome the aforementioned limitations regarding brush manufacturing. [Overview of the Initiative] [Problems that the invention aims to solve] 【0008】 This invention has been made in view of the limitations of existing brush manufacturing equipment, and provides a brush manufacturing apparatus that improves throughput by shortening waiting times between processes, reducing waste of raw materials, and minimizing defective products. [Means for solving the problem] 【0009】 In one embodiment, an embodiment of the present disclosure provides a brush manufacturing apparatus. The aforementioned brush manufacturing apparatus, Rotary conveying mechanism, Hair carrier loading station, One or more hair distribution stations, Ultrasonic fusion station and Heating station and Retrieval station and Logical controller system and, Equipped with, The aforementioned one or more hair distribution stations are Hair supply mechanism, Hair strands are shiny, Hair planting feeder, Equipped with, The aforementioned hair implantation feeder implants high-density, short-length hair bundles onto a hair carrier having finely spaced openings. The logic controller system provides programmed commands, controls the machine sequence, and monitors feedback on the operating status at each station through a network of sensors and actuators. 【0010】 In another embodiment, embodiments of the present disclosure provide a system for manufacturing brushes. The aforementioned brush manufacturing system Rotary conveying mechanism, Hair carrier loading station, One or more hair distribution stations, Ultrasonic fusion station and Heating station and Retrieval station and Logical controller system and, Equipped with, The logic controller system provides programmed commands, controls the machine sequence, and monitors feedback on the operating status at each station through a network of sensors and actuators. [Brief explanation of the drawing] 【0011】 The drawings provided herein disclose exemplary embodiments of the claimed inventions. Detailed descriptions and preparations of well-known compounds / substances / elements are omitted so as not to unnecessarily obscure the embodiments herein. Other objects, features and advantages of the present invention will become apparent from the following description, with reference to the accompanying drawings. [Figure 1A] Figure 1A shows a schematic diagram of the present invention according to one embodiment of the present disclosure. [Figure 1B] Figure 1B shows an example of a hair carrier according to an exemplary embodiment of the present disclosure. [Figure 2A] Figure 2A shows an example of a hair supply mechanism according to an exemplary embodiment of the present disclosure. [Figure 2B] Figure 2B shows an example of a hair picker according to an exemplary embodiment of the present disclosure. [Figure 2C]FIG. 2C shows an example of a nozzle according to an exemplary embodiment of the present disclosure. [Figure 2D] FIG. 2D shows an example of a cross-sectional view of a blower and suction system according to an exemplary embodiment of the present disclosure. [Figure 3] FIG. 3 shows an example of an ultrasonic device according to an exemplary embodiment of the present disclosure. 【Mode for Carrying Out the Invention】 【0012】 This section intends to provide explanations and descriptions of various possible embodiments of the present invention. Embodiments used herein, as well as their various features and advantageous details, are more fully described with reference to the non-limiting embodiments shown in the accompanying drawings and detailed in the following description. Examples used herein are only intended to facilitate the understanding of how embodiments can be implemented and enable those skilled in the art to implement the embodiments used herein. Also, the examples / embodiments described herein should not be construed as limiting the scope of the embodiments herein. 【0013】 Referring to FIG. 1, an embodiment of the present disclosure provides a brush manufacturing apparatus (100), The brush manufacturing apparatus (100) includes a rotary transfer mechanism (160), a hair carrier loading station (110), one or more hair distribution stations (120a - 120d), an ultrasonic fusion station (130), a heating station (140), an unloading station (150), a logic controller system, and the one or more hair distribution stations (120a - 120d) include a hair supply mechanism (200), a hair bundle picker (240), a hair planting feeder (250), and The aforementioned hair implantation feeder implants high-density, short-length hair bundles onto a hair carrier (170) having fine-pitched openings. The logic controller system provides programmed commands, controls the machine sequence, and monitors feedback on the operating status at each station through a network of sensors and actuators. 【0014】 The brush manufacturing apparatus (100) further comprises a network of sensors and actuators, the network of sensors and actuators being controlled by a logic controller system, the logic controller system enabling a pre-programmed sequence of processing steps. 【0015】 The stations (110, 120a-120d, 130-150) of the brush manufacturing apparatus (100) are connected by a rotary conveying mechanism (160) that stops at each station. The rotary conveying mechanism (160) is preferably a turntable. 【0016】 The movement of the rotary transport mechanism (160) is controlled by a servo motor. Here, station 1 is a hair carrier loading station (110), station 2 is a hair distribution station (120a-120d), station 3 is an ultrasonic fusion station (130) that seals the hair carrier opening (172), station 4 is a heating station (140) that securely fixes the hair bundles to the hair carrier (170), and station 5 is an extraction station (150). 【0017】 Furthermore, multiple hair distribution stations (120a to 120d) can be provided to distribute hair to various rows and columns of the hair carrier opening (172). The number of hair distribution stations (120a to 120d) depends on the row and column configuration of the hair carrier opening (172). In an exemplary embodiment of this device, there are four hair distribution stations (120a to 120d). 【0018】 The hair carrier loading station (110) comprises a vibrating feeder bowl, an orientation check feature, and a gripper arm, the gripper arm having a presence sensor that controls the movement of the gripper arm. The vibration of the vibrating feeder bowl is provided by a rotary vibrating exciter. The hair carrier (170) is loaded into the vibrating feeder bowl. This vibration causes the hair carrier (170) to move in an upward spiral until it is properly oriented and transported along the track to the hair carrier loading station (110) for pickup. The orientation check feature ensures that the hair carrier is properly oriented for the pick-and-place unit. When the presence sensor detects the hair carrier (170), the gripper arm delivers the hair carrier (170) to a rotary turntable. A second presence sensor activates the rotation of the rotary transport mechanism (160). 【0019】 Referring to Figures 2A to 2D, the hair distribution stations (120a to 120d) include a hair supply mechanism (200) along with a hair bundle picker (240) and a hair implantation feeder (250). Furthermore, the hair supply mechanism (200) includes a magazine (210) for hair bundles, and the magazine (210) has a vertical compression plate (230) and a horizontal compression plate (220), which are controlled by a solenoid valve and a reed switch. 【0020】 The bristles are manually loaded into the magazine (210). A vertical compression plate (230) is designed to move vertically to ensure that the bristles are at the same height. A horizontal compression plate (220) pushes the bristles horizontally toward the bristles picker (240). The simultaneous double compression operation continuously supplies the same number of bristles to the bristles picker (240). To minimize in-process waste, the bristles are pre-cut to a specific length and supplied at the required density. 【0021】 The hair bundle picker (240) comprises a picker plate (241), the picker plate (241) having a picker surface (242) with one or more through holes (244), the through holes (244) having dimensions that match the through holes of the hair carrier opening (172). The shape of the through holes (244) is preferably semicircular, but not limited thereto. Furthermore, sensors are used to detect hair bundles in all the through holes (244) of the picker plate. The control mechanism then slides the picker plate (241) and the horizontal compression plate (220) into clamp positions. To prevent hair bundles from entering the conveyor line (270), the hair bundles are clamped at the top and bottom. 【0022】 Furthermore, as shown in Figure 2C, the hair implantation feeder (250) is equipped with a conical nozzle (252). The conical nozzle (252) includes a first opening (254) and a second opening (256), the diameter of which is greater than the diameter of the second opening (256). The first opening (254) of the conical nozzle (252) receives the distal end of the conveyor line (270). The conical nozzle (252) receives hair bundles from the first opening (254) to the second opening (256) through the conveyor line (270) via a blower and suction system (260). The diameter of the second opening (256) is smaller than the diameter of the through-hole of the hair carrier opening (172). 【0023】 The conical nozzle (252) allows for fine-pitch distribution of the hair bundles, taking into account the sharp angles due to the curved profile of the hair carrier (170). When a hair carrier (170) is detected, a stopper at the distal end of the conical nozzle (252) retracts. The conical nozzle (252) moves in a vertical motion toward the hair carrier (170). The conical nozzle (252) is set to stop directly above each hair carrier opening (172). In an exemplary embodiment, the distance between the conical nozzle (252) and the hair carrier opening (172) may be less than 5 mm. Each conical nozzle (252) is positioned to overlap with others and oriented at a specific angle to the target hair carrier opening (172). By the operation of a high-pressure blower and a vacuum suction machine, the hair bundles are transported through the conveyor line (270) into the hair implantation feeder (250). Within the bristle implantation feeder (250), bristle bundles are implanted into each bristle carrier opening (172) by the pushing of a high-pressure blower and the pulling of a vacuum suction machine. When the discharge of a bristle bundle is detected, the bristle implantation feeder (250) moves vertically away from the bristle carrier. Before the bristle implantation feeder (250) retracts, a low-pressure blower is activated. Suction from the vacuum chamber pulls the bristle bundles down and simultaneously applies a second pressure through the bristle implantation feeder (250). This second pressure is lower than the first pressure. This pressure maintains the bristle bundles in the bristle carrier openings (172) and prevents the bristle bundles from clogging the cone feeder when the cone feeder is retracted. 【0024】 As shown in Figure 2D, the blower and suction system (260) comprises a high-pressure blower, a low-pressure blower, a vacuum suction machine, a transport line (270) having a conical nozzle (252) at its distal end, and a stopper. In an exemplary embodiment, there are four transport lines (270) in the hair distribution stations (120a to 120d). When a hair carrier (170) is placed in the hair implantation feeder (250), a presence sensor is activated. When the hair carrier (170) is detected, the stopper is released and the hair implantation feeder (250) moves vertically toward the hair carrier (170). This creates an unobstructed path from the hair bundle in the hair bundle picker (240) to the hair carrier (170) at the end of the transport line (270). The hair bundle moves forward toward the hair carrier (170) due to the operation of the high-pressure blower and vacuum suction machine. Once the bristles are discharged into the bristles carrier opening (172), the bristles feeder (250) moves vertically upward to its zero or non-operating position. To ensure that the bristles remain within the bristles carrier opening (172), the high-pressure blower is switched off and the low-pressure blower is activated. When the bristles feeder (250) is in the zero position, the high-pressure blower, low-pressure blower, and vacuum suction machine are stopped. Next, a stopper is extended at the distal end of the conveyor line (270). The timing and pressure settings of the high-pressure blower, low-pressure blower, and vacuum suction machine ensure that the bristles are conveyed and held within the opening of the bristles carrier opening (172). 【0025】 The blower and suction system (260) is controlled by a logic controller system. The logic controller system changes the pressure difference applied to the hair bundles. The pressure difference is changed by monitoring and modifying the pressure of the blower and suction. The logic controller system also monitors and manages the operation and stop sequences and timing between the blower and suction to supply the hair bundles through the conical nozzle (252) and the transport line (270), and to provide the pressure difference necessary to hold the hair bundles in the hair carrier opening (172) after planting when the blower and suction system (260) is stopped. The hair carrier (170) is transported to the next station with the hair bundles held in the hair carrier opening (172). 【0026】 Referring to Figure 3, the ultrasonic fusion station (130) comprises a power supply, a transducer, a transducer, and an ultrasonic horn (132). The ultrasonic horn (132) is preferably shaped to conform to the external shape and dimensions of the hair carrier (170). When the ultrasonic horn (132) is pressed against the hair carrier (170), it transfers energy to the energy director (174) functional part on the hair carrier (170). The concentrated energy allows the material of the energy director (174) to melt and flow into the hair carrier opening (172). The material of the energy director (174), when the process is optimized, completely fills the hair carrier opening (172). The desired result from this process is to seal the hair carrier opening (172) from the distal end and to retain the hair bundle within the hair carrier (170). 【0027】 The heating station (140) comprises a heating controller and a heating element, the heating element having a heating plate, the heating plate having a shape that conforms to the external shape and dimensions of the hair carrier (170). The purpose of the heating station is to increase the holding strength of the hair. This is achieved by melting the distal end of the hair bundle, resulting in the hair bundle material forming a thickened end. This allows the hair bundle to be firmly embedded in the sealed hair carrier opening (172). The hair bundle after heating in the hair carrier (170) has high holding strength. 【0028】 The retrieval station (150) includes a presence sensor and a pick-and-place gripper. When a hair carrier (170) is detected by the presence sensor at the retrieval station (150), the hair carrier (170), which is filled with hair, is retrieved for assembly. 【0029】 In another embodiment, A system (100) for manufacturing brushes is Rotary conveying mechanism (160), Hair carrier loading station (110), One or more hair distribution stations (120a~120d), Ultrasonic fusion station (130), Heating station (140), Retrieval station (150), Logical controller system and, Equipped with, The logic controller system provides programmed commands, controls the machine sequence, and monitors feedback of the operating status at each station through a network of sensors and actuators. The system (100) for manufacturing brushes further comprises a network of sensors and actuators, which is controlled by the logic controller system, which enables processing steps of a pre-programmed sequence. 【0030】 As will be readily apparent to those skilled in the art, the present invention can be readily manufactured in other specific forms without departing from its essential composition and properties. This embodiment should be construed as merely illustrative and non-limiting, and the scope of the invention is indicated by the claims rather than the foregoing description, and therefore all modifications that fall within that scope are intended to be incorporated into the invention.

Claims

[Claim 1] A brush manufacturing apparatus, the brush manufacturing apparatus, Rotary conveying mechanism (160), Hair carrier loading station (110), One or more hair distribution stations (120a to 120d), Ultrasonic fusion station (130), Heating station (140), Retrieval station (150), Logical controller system and, Equipped with, The one or more hair distribution stations (120a to 120d) are, Hair supply mechanism (200), Hair bundle shining (240) and, Hair planting feeder (250), Equipped with, The hair implantation feeder (250) implants high-density, short-length hair bundles onto a hair carrier (170) having fine-pitched openings. The aforementioned logic controller system provides programmed commands, controls machine sequences, and monitors feedback on the operating status at each station through a network of sensors and actuators. The hair implantation feeder (250) is equipped with a conical nozzle (252), the conical nozzle (252) includes a first opening (254) and a second opening (256), the diameter of which the first opening (254) is greater than the diameter of the second opening (256), and the diameter of the second opening (256) is smaller than the diameter of the through-hole of the hair carrier opening (172). Brush manufacturing equipment. [Claim 2] A brush manufacturing apparatus according to claim 1, The hair carrier loading station (110) is Vibrating feeder bowl and Orientation check function unit, Gripper arm and Equipped with, The gripper arm has a presence / absence sensor that controls the movement of the gripper arm. Brush manufacturing equipment. [Claim 3] A brush manufacturing apparatus according to claim 1, The hair supply mechanism (200) is Magazine for hair bundles (210) Equipped with, The magazine (210) has a vertical compression plate (230) and a horizontal compression plate (220), The vertical compression plate (230) and the horizontal compression plate (220) are controlled by a solenoid valve and a reed switch. Brush manufacturing equipment. [Claim 4] A brush manufacturing apparatus according to claims 1 and 3, The aforementioned hair bundle picker (240) is Picka Plate (241) Equipped with, The picker plate (241) has a picker surface (242) having one or more through holes (244), The through-hole (244) has dimensions that coincide with the through-hole of the hair carrier opening (172), The shape of the through hole (244) may be semicircular. Brush manufacturing equipment. [Claim 5] A brush manufacturing apparatus according to claim 1, The conical nozzle (252) receives the distal end of the conveyor line (270) at the first opening (254). Brush manufacturing equipment. [Claim 6] A brush manufacturing apparatus according to claims 1 and 5, The conical nozzle (252) receives the hair bundle from the first opening (254) to the second opening (256) via a blower and suction system (260) and a transport line (270). Brush manufacturing equipment. [Claim 7] A brush manufacturing apparatus according to claim 1, The ultrasonic fusion station (130) is Ultrasonic horn (132) Equipped with, The ultrasonic horn (132) has a shape that conforms to the external shape and dimensions of the hair carrier (170). Brush manufacturing equipment. [Claim 8] A brush manufacturing apparatus according to claim 1, The heating station (140) is Heating element Equipped with, The heating element has a heating plate, The heating plate has a shape that conforms to the outer shape and dimensions of the hair carrier (170). Brush manufacturing equipment. [Claim 9] A brush manufacturing apparatus according to claim 1, The aforementioned retrieval station (150) is Existence sensor and Pick and place grippers, Equipped with, Brush manufacturing equipment. [Claim 10] A brush manufacturing apparatus according to any one of claims 1 to 9, wherein the brush manufacturing apparatus further comprises: Sensor and actuator network Equipped with, The network of sensors and actuators is controlled by the logic controller system. The logic controller system enables processing steps of a pre-programmed sequence. Brush manufacturing equipment. [Claim 11] A system for manufacturing brushes, wherein the brush manufacturing system is Rotary conveying mechanism (160), Hair carrier loading station (110), One or more hair distribution stations (120a to 120d), Ultrasonic fusion station (130), Heating station (140), Retrieval station (150), Logical controller system and, Equipped with, The one or more hair distribution stations (120a to 120d) are, Hair supply mechanism (200), Hair bundle shining (240) and, Hair planting feeder (250), Equipped with, The hair implantation feeder (250) implants high-density, short-length hair bundles onto a hair carrier (170) having fine-pitched openings. The aforementioned logic controller system provides programmed commands, controls machine sequences, and monitors feedback on the operating status at each station through a network of sensors and actuators. The hair implantation feeder (250) is equipped with a conical nozzle (252), the conical nozzle (252) includes a first opening (254) and a second opening (256), the diameter of which the first opening (254) is greater than the diameter of the second opening (256), and the diameter of the second opening (256) is smaller than the diameter of the through-hole of the hair carrier opening (172). Brush manufacturing system. [Claim 12] A system for manufacturing a brush according to claim 11, wherein the brush manufacturing system further comprises: Sensor and actuator network Equipped with, The network of sensors and actuators is controlled by the logic controller system. The logic controller system enables processing steps of a pre-programmed sequence. Brush manufacturing system.

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