Machine for making brushes

Abstract

A machine (1) for making brushes (100) comprises supply means (2) for unwinding a metal wire (101) from a reel; a first operating station (3) for cutting the wire (101), making wire sections (102) and bending them to obtain bent wire sections (103); a second operating station (4) for associating with each bent wire section (103) a respective bundle of bristles (110); a third operating station (5) for trimming the bundle of bristles (110) associated with the bent wire section (103); a first moving drum (6) provided with a plurality of operating units (7), each of which comprising gripping means (11, 12) for receiving, supporting and twisting a bent wire section (103); the operating stations (3, 4, 5) are positioned angularly spaced around the first moving drum (6) which is rotatable about a first rotation axis (XI) to position each operating unit (7) in sequence at each of the operating stations (3, 4, 5); while the operating unit (7) is moved from the second operating station (4) to the third operating station (5) the gripping means (11, 12) twist the bent wire section (103) to make a brush.

Description

[0001] Machine for making brushes

[0002] The present invention relates to machines for making small and elongated brushes, in particular brushes or small brushes of the so-called "twisted-in" type obtained by twisting two portions of metal wire bent over each other longitudinally so as to block a bundle of bristles or fibres.

[0003] Various types of machines are known for producing brushes and small brushes of the "twisted-in" type, such as cosmetic mascara brushes, interdental brushes, brushes for medical use and the like.

[0004] These machines comprise a plurality of operating stations in which the different operations that allow the brush to be made from a metal wire and a bundle of bristles or fibres are carried out in succession. In particular, as is known, in operating stations the wire unwound from a reel is cut to size to have a section or portion of defined length, which is bent back on itself so as to receive a flattened bundle of bristles or fibres, then twisted to block the bristles and arrange them radially in a cylindrical shape.

[0005] Additional stations are generally provided in such machines for trimming the bristles in order to define the shape and size of the final bundle of bristles (for example cylindrical, conical, etc.), to cut the stem formed by the twisted metal wire and to have a brush of predetermined length, to check the quality of the brush made (linearity, arrangement of the bristles, etc.).

[0006] Suitable transfer means are provided in the known machines to automatically move and transfer the brushes being produced through the various operating stations till an exit station. In particular, machines provided with transfer means consisting of a turret or movement wheel, rotatable around a vertical axis and provided with a plurality of supports, angularly spaced from each other, each of which acts to support a respective brush in its various stages of construction, are known. Thereby, during the rotation of the turret each brush is transferred in sequence to the various operating stations.

[0007] To allow the execution of the various operations in the operating stations, the rotation of the turret takes place with intermittent motion and the stopping interval of this intermittent motion is determined by the duration of the operation that requires more time, typically the operation of twisting of the wire.

[0008] Due to the stopping time necessary for twisting the wire, the operating speed or cadence and therefore the productivity of known machines remains limited.

[0009] To overcome this disadvantage and reduce the stopping time, in some known machines the twisting operation is carried out in two distinct stations: a first torsion station in which the two portions of metal wire bent one on the other are partially twisted to block the bundle of bristles previously inserted between them, and a second torsion station in which the twisting of the two portions of metal wire is completed.

[0010] Thereby, it is possible to slightly increase the speed and productivity of the machine, which however becomes more complex and cumbersome by comprising two wire torsion stations. An object of the present invention is to improve the known machines for making small and elongated brushes, in particular brushes of the so-called "twisted-in" type.

[0011] Another object is to create a machine that allows high quality "twisted-in" brushes to be made even at high operating speeds or cadences, greater than those typical of known machines.

[0012] A further object is to provide a machine with precise and reliable operation.

[0013] These and other objects are achieved by a machine for making brushes according to one or more of the claims set forth below.

[0014] The invention can be better understood and implemented with reference to the attached drawings which illustrate an exemplary and non-limiting embodiment thereof, wherein: figure l is a perspective view of the machine for making brushes of the invention; figure 2 is a front view of the machine of figure 1; figure 3 is a perspective view of a first moving drum of the machine of figure 1; figure 4 is a perspective view of an operating unit of the first moving drum; figures 5 and 6 are side and front views respectively of the operating unit of figure 4 in an operating configuration; figures 7 to 10 are perspective views of the operating unit of figure 4 in different operating steps of making a brush; figures 11 and 12 are front and side views, respectively, of a first operating station for cutting and bending the wire in an initial step of descent of the wire; figure 13 is a perspective view of the first operating station of figure 11; figures 14 to 16 are side views of guiding and abutment means and a first transfer arm of the first operating station in three different bending steps of a wire section; figure 17 is a front view of the first transfer arm in a step of transferring a bent wire section to first gripping means of an operating unit of the first moving drum, not illustrated; figures 18 and 19 are side views of the first transfer arm and the first gripping means in respective steps of transfer of the bent wire section; figures 20A to 20C are enlarged side views, respectively, of a bent wire section, a bent wire section to which a bundle of bristles is associated, and a brush made by the machine of the invention; figure 21 is an enlarged and partial perspective view of a second operating station in which a bundle of bristles is associated with a bent wire section, supported by an operating unit of the first moving drum, not illustrated; figures 22 and 23 are schematic side views of the second operating station and an operating unit of the first moving drum in respective steps of inserting a bundle of bristles into the bent wire section; figures 24 and 25 are enlarged front views of a third operating station arranged to trim the bundle of bristles of a brush in a non-operating configuration and in an operating configuration respectively; figure 26 is a partial and perspective view of the third operating station with trimming means acting on a brush arranged in a first trimming position; figures 27 and 28 are partial and perspective views of the third operating station with trimming means acting on a brush arranged respectively in a second and a third trimming position; figures 29 and 30 are enlarged and partial views, respectively front and perspective, of transfer means in a step of picking up a brush from an operating unit of the first moving drum, not illustrated; figures 31 and 32 are enlarged and partial views, respectively front and perspective, of the transfer means in a step of inserting a brush in a seat of a second moving drum; figure 33 is an enlarged front view of the second moving drum and a fourth operating station arranged to perform quality checks on the brushes; figure 34 is a perspective view of the fourth operating station in a step of extracting a brush from a seat of the second moving drum; figures 35 and 36 are enlarged, interrupted, and perspective views of the machine of the invention, illustrating in particular the second moving drum, a reject station and a brush exit station.

[0015] With reference to figures 1 to 36, the machine 1 of the invention is illustrated, adapted to make brushes or small brushes 100 of the so-called "twisted-in" type, i.e. formed by a metal wire 101 bent and twisted so as to clamp a bundle of bristles 110.

[0016] The machine 1 comprises supply means 2 for unwinding a metal wire 101 from a reel, not illustrated and moving it along a feeding direction A, in particular along a moving plane M, a first operating station 3, a second operating station 4 and a third operating station 5 for performing operations on the wire and a first moving drum 6. The supply means 2, the operating stations 3, 4, 5 and the first feeding drum 6 are fixed to a main frame 40 of the machine 1 and more precisely are fixed to a support wall 41 of said main frame 40 which is parallel to the moving plane M and is in particular almost vertical. In particular, the first moving drum 6 is fixed to the rotatable support wall 41 with a first rotation direction SI (for example counterclockwise with reference to Figure 2) about a first rotation axis XI, the latter being orthogonal to the support wall 41 and to the moving plane M, i.e. almost horizontal.

[0017] The operating stations 3, 4, 5 are positioned angularly spaced from each other around the first moving drum 6.

[0018] The supply means 2 are of known type and are not described in detail and comprise a plurality of wheels or rollers around which the wire 101 is wound.

[0019] The first operating station 3 is configured to receive the wire 101 fed by the supply means 2 along the feeding direction A, cut it so as to create wire sections 102 of predefined length and then bend each wire section 102 with a "V" shape so as to obtain a bent wire section 103, formed by two wire portions 103a, in particular substantially side by side.

[0020] The second operating station 4 is arranged to associate a respective bundle of bristles 110 with each bent wire section 103, and the third operating station 5 is arranged to trim the bundle of bristles 110 associated with each bent wire section 103.

[0021] The first moving drum 6 is provided with a plurality of operating units 7, for example six, each comprising respective gripping means 11, 12 and related driving means 31, 32, 33, 34, 35 arranged to receive, support and twist a bent wire section 103. The first moving drum 6 rotatable about the first rotation axis XI, in particular with intermittent motion with the first rotation direction SI, positions each operating unit 7 in sequence at each of the operating stations 3, 4, 5.

[0022] More precisely, each operating unit 7 is positioned at the first operating station 3 to receive a bent wire section 103, which is grasped and supported by the respective gripping means 11, 12.

[0023] The operating unit 7 is positioned at the second operating station 4 so that a bundle of bristles 110 is associated with the bent wire section 103 supported by the gripping means 11, 12.

[0024] The operating unit 7 is then positioned at the third operating station 5 to allow trimming of the bundle of bristles.

[0025] While the operating unit 7 is transferred and moved from the second operating station 4 to the third operating station 5, the respective gripping means 11, 12 are activated so as to twist the bent wire section 103 on itself about a respective longitudinal axis W with the bundle of bristles 110 so as to block the latter and make a brush 100. In other words, the bent wire section 103 with the bundle of bristles 110 is twisted in each operating unit 7 while the first drum is rotated about the first rotation axis XI, in particular in the section separating the second operating station 4 from the third operating station 5.

[0026] With particular reference to Figures 3 to 10, each operating unit 7 comprises in particular first gripping means 11 configured to grasp a bent end 103b of the bent wire section 103 and second gripping means 12 for grasping free ends 103 c of the bent section 103.

[0027] The first gripping means 11 are operable in rotation about a torsion axis B by means of first driving means 31, present in the operating unit 7, so as to twist the two wire portions 103a of the bent wire section 103 onto each other about the respective longitudinal axis W. The gripping means 11, 12 grasp and hold the bent wire section 103 so that the longitudinal axis W along which they extend is almost coaxial with the torsion axis B.

[0028] Each operating unit 7 further comprises second driving means 32 for linearly moving the second gripping means 13, in particular parallel to the torsion axis B, for selectively grasping or releasing the free ends 103c of the bent section 103, as better explained in the following description.

[0029] Each operating unit 7 also comprises clamping means 24 configured to bring the wire portions 103a closer together and into abutment with each other at the bent end 103b of the bent wire section 103 so as to block a respective bundle of bristles 110 that is inserted between the aforementioned wire portions 103a in the second operating station 4.

[0030] Thereby, moreover, the free ends 103c of the two wire portions 103a are also brought into mutual abutment so as to be grasped and blocked by the second gripping means 12.

[0031] The clamping means 24 are actuated by third driving means 33 that are present in the operating unit 7, and comprise a pair of respective jaws.

[0032] The operating unit 7 also comprises fourth driving means 34 and fifth driving means 35, of known type and therefore not described in detail, arranged to drive respectively the first gripping means 11 and the second gripping means 12 selectively in closing or opening to block or release the bent wire section 103.

[0033] With particular reference to figures 11 to 19, the first operating station 3 comprises cutting means 17 for slidably guiding the wire 101 moved by the supply means 2 along the feeding direction A and cutting it to make a wire section 102 of predefined length.

[0034] The first operating station 3 also includes guiding and abutment means 18 for slidably guiding the wire 101 along the feeding direction A and a first transfer arm 20 provided with a first end 20a supporting a bending element 21 and third gripping means 13. The cutting means 17 and the guiding and abutment means 18 are fixed to the support wall 41 of the main frame 40.

[0035] The cutting means 17 comprise a knife 67 movable linearly transversally to the feeding direction A so as to cut or shear the wire 101 to obtain a wire section 102. The distance between the cutting means 17 and the guiding and abutment means 8 is adjustable to obtain wire sections 102 having a fixed length.

[0036] The first transfer arm 20 is movable, in particular transversally to the moving plane M, so as to push the bending element 21 against the guiding and abutment means 18 and bend the wire section 102 supported by them almost into a "V" shape so as to form a corresponding bent wire section 103. The bending element 21 is for example a flat sheet or tab fixed to the first end 20a of the first transfer arm 20 and protruding towards the guiding and abutment means 18.

[0037] The third gripping means 13 are configured and operable for grasping and blocking the bent wire section 103 during and after bending. The third gripping means 13 comprise a respective gripper with two jaws actuated to open and close by respective actuator means, of known type and not illustrated, for example of the pneumatic type.

[0038] The guiding and abutment means 18 comprise a pair of rollers 68 mounted idle on respective support elements 65, 66, in particular facing and opposed so as to form a slot 69 of predefined height inside which the wire section 102 pushed by the bending element 21 is inserted and bent.

[0039] The first transfer arm 20 is also movable, in particular both parallel and almost orthogonal to the moving plane M, as better explained in the following description, in order to transfer the bent wire section 103, blocked and held by the third gripping means 13, to the first gripping means 11 of an operating station 7 arranged adjacent to the first operating station 3 by the first moving drum 6.

[0040] In particular, the first transfer arm 20 is movable along and around a transfer axis X5, almost orthogonal to the moving plane M, actuated by respective moving means of known type, not described in detail and not illustrated in the figures, supported by the support wall 41 of the main frame 40.

[0041] With particular reference to Figures 21 to 23, the second operating station 4 comprises a supply magazine 23 suitable for housing a plurality of bundles of bristles 110, in particular arranged aligned and side by side along a supply direction S, and fourth gripping means 14 arranged to take one bundle of bristles 110 at a time and insert it between the two wire portions 103a of a bent wire section 103 supported and held by the first gripping means 11 of an operating unit 7 arranged by the first moving drum 6 adjacent to the second operating station 4.

[0042] More precisely, the fourth gripping means 14 comprise a respective pair of jaws adapted to grasp / release a flattened bundle of bristles 110 and moving means 44, of known type (figures 1 and 2), adapted to move the aforementioned pair of jaws from an inactive position to a position for picking up the bundle of bristles 110 from the supply magazine 23 (fig. 22) to a position for inserting the bundles of bristles 110 between the two wire portions 103a of the bent wire section 103 supported and held at its bent portion 103b by the first gripping means H (fig. 23).

[0043] With particular reference to figures 24 to 28, the third operating station 5 comprises trimming means 25, 26 defining a cutting edge 27 and selectively movable along a cutting direction T to approach or move away from a brush 100 supported by an operating unit 7 arranged adjacent, respectively to trim and disengage a bundle of bristles 110 of the brush 100.

[0044] In particular, the trimming means 25, 26 comprise a rotary cutter 25 and a counter knife 26 both cooperating to form the cutting edge 27 that interacts and cuts the bundle of bristles 110.

[0045] The trimming means 25, 26 are also movable around an adjustment axis Y in order to change an angle a of the cutting edge 27 with respect to the longitudinal axis W of the brush 100, for example to shape the bundle of bristles 110 into a frustoconical shape (Figs. 27 and 28). The third operating station 5 therefore comprises a first supporting element 51 adapted to support the rotary cutter 25 rotatably about a respective rotation axis and sixth driving means 36 adapted to rotate the rotary cutter 25 about its rotation axis.

[0046] The first support element 51 is in turn rotatably supported by a second support element 52 of the third operating station 5 so as to rotate, and with them the trimming means 25, 26 about the adjustment axis Y. The second support element 52 also supports seventh driving means 37 adapted to rotate the first support element 51 about the adjustment axis Y.

[0047] The second support element 52 is slidably fixed to a third support element 53 of the third operating station 5 which is in turn fixed to the support wall 41.

[0048] The second support element 52 is moved by eighth moving means 38 along the cutting direction T so as to bring the trimming means 25, 26 closer to the brush 100 in a trimming position (fig. 25) or to move the trimming means 25, 26 away from the brush 100 in a disengaging position (fig. 24).

[0049] The machine 1 of the invention further comprises a fourth operating station 8 for carrying out quality checks on each brush 100 made in the first moving drum 6 in order to identify brushes 100 compliant with defined quality requirements and brushes 100 non-compliant with quality requirements.

[0050] The machine 1 also comprises an exit station 10, in which the brushes 100, in particular the brushes 100 compliant with the required quality requirements, are taken and transferred out of the machine 1, and a reject station 9, in which the brushes 100 non-compliant with the required quality requirements are taken and transferred out of the machine 1.

[0051] In the illustrated embodiment, the machine 1 comprises a second moving drum 60 next to the moving drum 6 and provided with a plurality of seats 61, each of which is adapted to receive and support a respective brush 100 received by the first moving drum 6.

[0052] The second moving drum 60 is rotatable, in particular with intermittent motion, about a second rotation axis X2, in particular parallel to the first rotation axis XI, with a second rotation direction S2 (for example clockwise with reference to Figure 2) and is configured to position each brush 100 in sequence at the fourth operating station 8, in which quality checks are carried out on said brush 100, at the reject station 9, in which a brush 100 non- compliant with the required quality requirements is taken and transferred out of the machine 1, and at the exit station 10, in which a brush 100 compliant with the required quality requirements is taken transferred out of the machine 1.

[0053] The fourth operating station 8, the reject station 9 and the exit station 10 are positioned angularly spaced around the second moving drum 60.

[0054] The second moving drum 60 is fixed rotatably about the second rotation axis X2 on the support wall 41 and comprises, for example, six seats 61 arranged angularly and regularly spaced along a peripheral edge of the aforementioned second moving drum 60. The seats 61 comprise cylindrical cavities having respective longitudinal axes K parallel to the second rotation axis X2 and are adapted to receive and retain a head 100a of the brush 100 provided with the bundle of bristles 110 (fig. 20C).

[0055] The machine 1 comprises transfer means 19 positioned downstream of the third operating station 5, with reference to the first rotation direction SI of the first moving drum 6 about the first rotation axis XI, and configured to pick up one brush 100 at a time from a respective operating unit 7 and then insert it into a respective seat 61 of the second moving drum 60. More precisely and with particular reference to Figures 29 and 30, the transfer means 19 comprise a second transfer arm 22 provided with a second end 22a that supports the sixth gripping means 16. The second transfer arm 22 is movable, in particular both transversally and parallel to the moving plane M, so as to grasp, by means of the sixth gripping means 16, one brush 100 at a time from a respective operating unit 7 and then transfer it, insert it and release it in a respective seat 61 of the second moving drum 60.

[0056] More precisely, the second transfer arm 22 is fixed to a fourth support element 54 slidably connected to a fifth support element 55. The fifth support element 55 is fixed to the support wall 41 rotatably about a third rotation axis X3, particularly parallel to the first rotation axis XI, so as to allow the rotation of the second transfer arm 22 between a picking position for allowing the sixth gripping means 16 to grasp a brush 100 held by the first gripping means 11 in the respective operating unit 7 (Figs. 29 and 30) and a first release position for positioning the sixth gripping means 16 with the brush 100 in front of a seat 61 of the second moving drum 60 (Figs. 31, 32).

[0057] The fourth support element 54 is movable along an insertion direction C almost parallel to the second rotation axis X2 and to a longitudinal axis K of the seat 61, so as to allow the second transfer arm 22 to be moved to a second release position in which the sixth gripping means 16 insert inside the seat 61 and then release a brush 100. More precisely, the head 100a of the brush 100 provided with the bundle of bristles 110 is inserted in the seat 61, almost cylindrical, and held therein by means of the flexibility of the bristles themselves.

[0058] The sixth gripping means 16 comprise a respective gripper with two jaws actuated to open and close by respective actuator means, for example of a pneumatic type, of a known type not illustrated in the figures.

[0059] The fourth support element 54 and the fifth support element 55 are respectively moved linearly along the insertion direction C and rotatably around the third rotation axis X3 by respective driving means of type that is known and not illustrated in the figures.

[0060] With particular reference to figures 33 and 34, the fourth operating station 8, in particular fixed to the support wall 41 of the machine 1, comprises vision means 28 configured to acquire at least one image of each brush 100 and a checking unit 50 adapted at least to compare the detected image with a sample image.

[0061] The fourth operating station 8 further includes lighting means 29 arranged to completely and uniformly illuminate the brush 100 of which the vision means 28 must acquire one or more images to be analysed.

[0062] The vision means 28 and the lighting means 29 are adjustably connected to a support beam 42 in turn fixed to the support wall 41.

[0063] The fourth operating station 8 further comprises fifth gripping means 15 arranged to grasp a single brush 100, extract it from the respective seat 61 of the second moving drum 60, rotate it about the respective longitudinal axis W to allow vision means 28 to acquire at least one image and then reinsert it in the respective seat 61. The fifth gripping means 15 comprise a respective gripper with two jaws actuated to open and close by respective actuator means, for example of a pneumatic type, of a known type and not illustrated in the figures.

[0064] The fifth gripping means 15 are rotatably supported by a sixth support element 56 and placed in rotation by ninth moving means 39 about a fourth rotation axis X4, substantially coaxial to a longitudinal axis of the seat 61, when the latter is arranged by the second moving drum 60 at the fourth operating station 8. In particular, the ninth moving means 29 make it possible to rotate the brush 100 around its longitudinal axis W when grasped by the fifth gripping means 15. The sixth support element 56 is slidably supported by a seventh support element 57 in turn fixed to the support beam 42.

[0065] The sixth support element 56 is moved along a disengagement direction D, almost parallel to the fourth rotation axis X4, by tenth driving means 45.

[0066] With particular reference to figures 1, 2 and 35, the reject station 9 comprises first picking means 70 arranged to take and extract one at a time from a respective seat 61 of the second moving drum 60 the brushes 100 non-compliant with the required quality requirements.

[0067] The first picking means 70 comprise a first picking arm 72 provided with seventh gripping means 73 and movable along a first extraction direction E, in particular almost parallel to the second rotation axis X2 of the second drum and to the longitudinal axis K of the seats 61, so as to extract from the latter the non-compliant brushes 100 and then release them into an underlying first collection container 71.

[0068] The first picking arm 72 is fixed to a first support rod 74 slidably connected to a first tube 75 fixed to the support wall 41 and linearly actuated along the first extraction direction E by respective moving means of known type and not illustrated in the figures.

[0069] The seventh gripping means 73 comprise a respective gripper with two jaws actuated to open and close by respective actuator means, for example of a pneumatic type, of a known type and not illustrated in the figures.

[0070] The exit station 10 comprises second picking means 80 arranged to pick up and extract one at a time from a respective seat 61 of the second moving drum 60 brushes 100 compliant with the required quality requirements.

[0071] The second picking means 80 comprise a second picking arm 82 provided with eighth gripping means 83 and movable along a second extraction direction F, in particular almost parallel to the second rotation axis X2 of the second moving drum 60 and to the longitudinal axis K of the seats 61, so as to extract from the latter the compliant brushes 100 and then release them into a second collection container 81. The second picking arm 82 is fixed to a second support rod 84 slidably connected to a second tube 85 fixed to the support wall 41 and linearly actuated along the second extraction direction E by respective moving means of known type and not illustrated in the figures.

[0072] The operation of the machine 1 of the invention adapted to make brushes or small brushes 100 of the "twisted-in" type, formed by a metal wire 101 bent and twisted so as to clamp a bundle of bristles 110, provides that the supply means 2 unwind the metal wire 101 from a reel and move it along the feeding direction A towards the first operating station 3 where the first transfer arm 20 and the guiding and abutment means 18 block the wire 101 to allow the cutting means 17 to cut it and make a wire section 102 of predefined length.

[0073] In particular, the knife 67 of the stopping and cutting means 17 is actuated linearly transversally to the feeding direction A so as to cut or shear the wire 101 after the latter has been blocked by the bending element 21 against the guiding and abutment means 18. For this purpose the first transfer arm 20 is moved linearly, parallel to the transfer axis X5, towards the guiding and abutment means 18.

[0074] At this point the wire section 102 of defined length obtained by cutting the wire 101 is supported and blocked between the bending element 21 and the guiding and abutment means 18.

[0075] The first transfer arm 20 is further moved along the transfer axis X5 towards the guiding and abutment means 18 so as to bend the wire section 102 - pushed by the bending element 21 between the two rollers 68, i.e. inside the slot 69 - into a "V" shape and obtain a bent wire section 103. The third gripping means 13 of the first transfer arm 20 are then actuated to close in order to grasp and block the bent wire section 103.

[0076] The first transfer arm 20 is then moved along the transfer axis X5 so as to disengage and move away the bending element 21 and the bent wire section 103 from the guiding and abutment means 18 and is then rotated around the transfer axis X5 so as to position the bent wire portion 103 in front of the first gripping means 11 of an operating unit 7 of the first moving drum 6.

[0077] The first transfer arm 20 is moved along the transfer axis X5 towards the first gripping means 11 to give the bent wire portion 103 to the latter.

[0078] The first gripping means 11 is actuated to close by the fourth driving means 34 to block the bent wire section 103 at its bent end 103b.

[0079] At this point the third gripping means 13 release the bent wire section 103 and the first transfer arm 20 is returned to its initial position in which the bending element 21 and the third gripping means 13 are facing but spaced apart from the guiding and abutment means 18.

[0080] At the same time, the moving drum 6 is rotated around the first axis XI, for example by 60°, to move the operating unit 7 which has received in the first operating station 3 a bent wire section 103, in the second operating station 4, in which the fourth gripping means 14 take a bundle of bristles 110 from the supply magazine 23 and insert it between the two wire portions 103a of the bent wire section 103 supported and held by the first gripping means 11. More precisely, the moving means 44 move the pair of j aws of the fourth gripping means 14 in sequence between the inactive position, in which the fourth gripping means 14 are further spaced from the supply magazine 23 and from the second moving drum 6, the picking position of the bundle of bristles 110, in which the jaws of the fourth gripping means 14 are actuated to close in order to grasp a bundle of bristles 110 from the supply magazine 23, and the insertion position in which the gripping means 14 insert and then release the bundle of bristles 110 between the two wire portions 103a of the bent wire section 103.

[0081] Before releasing the bundle of bristles 110, by actuating the jaws of the fourth gripping means 14 to open, the jaws of the clamping means 24 of the operating unit 7 are actuated to close by the third driving means 33 so as to approach and abut the wire portions 103a at the bent end 103b of the bent wire section 103 and thus block the bundle of bristles 110 inserted therein. In this way, the fourth gripping means 14 can release the bundle of bristles 110 and be returned by the moving means 44 to the inactive position and the second gripping means 12 are able to grasp and block the free ends 103 c of the wire bent section 103.

[0082] For this purpose, the second gripping means 12 are linearly moved by the second driving means 32 parallel to the torsion axis B from a respective inactive position in which they are spaced from the free ends 103c of the bent section 103 (fig. 5 and 7) to a respective active position in which they are adjacent to the free ends 103c (fig. 8) and can be actuated to close by the fifth driving means 35 to gasp and block the aforementioned free ends 103c.

[0083] At this point, with the second gripping means 12 blocked in place and not rotatable, the first gripping means 11 are actuated in rotation around the torsion axis B by the first driving means 31 so as to twist the two wire portions 103 a of the bent wire section 103 onto each other, around the respective longitudinal axis W so as to open the bundle of bristles 110 in a cylindrical shape and make a brush 100.

[0084] It should be noted that the rotation of the first gripping means 11, i.e. the torsion or twisting step of the bent wire section 103, takes place during the movement of the operating unit 7 from the second operating station 4 to the third operating station 5, i.e. during the rotation of the first moving drum 6 with intermittent motion at an angle of 180° equal to three steps of movement of the intermittent motion. This time interval allows the wire 101 to be twisted in a controlled manner and in subsequent steps, allowing a high quality brush 100 to be made. In particular, the gripping means 11, 12 of the operating unit 7 are actuated by the relative driving means 31, 32, 33, 34, 35 in order to twist the bent wire section 103 onto itself and make a brush 100 during the stopping steps and / or the movement steps of the intermittent motion, while the first moving drum 6 is rotated so as to move the operating unit 7 from the second operating station 4 towards the third operating station 5.

[0085] In the fifth operating station 5, the second gripping means 12 release the brush 100 and are linearly moved by the second driving means 32 into the respective inactive position to allow the approach of the trimming means 25, 26 and the rotation of the brush 100 performed by the first gripping means 11 and necessary for trimming the bristles. More precisely, the trimming means 25, 26 are moved along the cutting direction T so as to abut the bundle of bristles 110, in particular by moving the second support element 52 slidably fixed to the third support element 53 by means of the eighth moving means 38.

[0086] The trimming means 25, 26 are also movable about the adjustment axis Y to change the angle a formed by the cutting edge 27 with the longitudinal axis W of the brush 100, for example to shape the bundle of bristles 110 into a frustoconical shape. To this end, the first support element 51, which supports the rotary cutter 25 and the counter knife 26 and is rotatably supported by the second support element 52, can be rotated by the seventh driving means 37 about the adjustment axis Y.

[0087] The first moving drum 6 is then rotated, once the trimming of the bundle of bristles 110 has been completed, in particular by an angle of 60°, so as to position the operating unit 7 supporting the brush 100 that has undergone the trimming of the respective bundle of bristles 110 at the transfer means 19 that pick up the brush 100 supported by the first gripping means 11 and transfer it to a seat 61 of the second moving drum 60.

[0088] For this purpose, the second transfer arm 22 is arranged in the picking position, in which the sixth gripping means 16 are able to grasp and hold a stem 100b of the brush 100 and then disengage the latter from the first gripping means 11, when actuated to open by the fourth driving means 34.

[0089] The second transfer arm 22 is then rotated around the third rotation axis X3 in the first release position and then moved linearly parallel to the third rotation axis X3 in the second release position so as to insert inside the seat 61 and then release the brush 100. For this purpose, the fifth support element 55, rotatably fixed to the support wall 41, is rotated about the third rotation axis X3 and the fourth support element 54 is moved along the insertion direction C. Once inserted inside the respective seat 61, the brush 100 is released by the sixth gripping means 16 of the second transfer arm 22 which are moved away from the second moving drum 60.

[0090] The second moving drum 60 is rotated around the second rotation axis X2 with intermittent motion coordinated to the intermittent motion of the first moving drum 6 so as to transfer the brush 100 to the fourth operating station 8 in which the vision means 28 acquire one or more images of the brush 100 which, for example, the checking unit 50 compares with sample images to identify brushes 100 compliant or non-compliant with defined quality requirements.

[0091] For this purpose, the fifth gripping means 15 of the fourth operating station 8 grasp the brush 100, in particular by clamping its stem 100b, they extract it from the respective seat 61 of the second moving drum 60 and rotate it around the respective longitudinal axis W to allow the vision means 28 to acquire images of it.

[0092] In particular, the sixth support element 56 that rotatably supports the fifth gripping means 15 is moved along the disengagement direction D by the tenth driving means 45 so as to extract the brush 100 from the seat 61 and therefore the jaws of the fifth gripping means 15 that clamp the stem 100b of the brush 100 are placed in rotation in a controlled manner by the ninth moving means 39 around the fourth rotation axis X4, which is substantially coaxial to the longitudinal axis K of the seat 61 to acquire images from different angles of the entire brush 100.

[0093] Once the necessary images have been detected, the fifth gripping means 15 are actuated so that the head 100a of the brush 100 is again inserted inside the respective seat 61 of the second moving drum 60.

[0094] A subsequent rotation of the second moving drum 60 allows the brush 100 to be transferred to the next reject station 9. In particular, if the brush 100 is not compliant, the jaws of the seventh gripping means 73 grasp the stem 100b of the brush 100 and the first picking arm 72, which supports the seventh gripping means 73, is moved along the first extraction direction E in order to extract and move the brush 100 away from the respective seat 61. The jaws of the seventh gripping means 73 are then actuated to open in order to release the non- compliant brush 100 into the underlying first collection container 71.

[0095] If the brush 100 instead complies with the quality requirements, it is moved by the second moving drum 60 at the exit station 10 in which the second picking means 80 pick up and extract the aforementioned brush 100 from the seat 61 and release it into the underlying second collection container 81. More precisely, the jaws of the eighth gripping means 83 grasp the stem 100b of the brush 100 and the second picking arm 82 supporting the eighth gripping means 83 is moved along the second extraction direction F so as to extract and move the brush 100 away from the respective seat 61. The jaws of the eighth gripping means 83 are then actuated to open in order to release the brush 100 into the underlying second collection container 81.

[0096] The machine 1 of the invention therefore makes it possible to produce small, elongated brushes of the "twisted-in" type of high quality operating at high speeds, higher than those typical of known machines. This is made possible by the fact that the longest operating step of the process of making the brush, i.e. the torsion or twisting step of the bent wire section 103 occurs during the movement and transfer of the operating units 7, which support a respective brush, from the second operating station 4 to the third operating station 5 i.e. during the rotation of the first moving drum 6 with intermittent motion by an angle of 180° equal to three steps of movement of the intermittent motion. This time interval (which comprises both the motion steps and the stopping steps of the intermittent rotation motion of the first moving drum 6) allows the bent wire section 103 to be twisted in a controlled manner and in subsequent steps, allowing a high quality brush 100 to be made.

[0097] Each operating unit 7 mounted on the first moving drum 6 is in fact provided with respective gripping means 11, 12 and related driving means 31, 32, 33, 34, 35, the gripping means 11, 12 being able to grasp a bent wire section 103 and twist it onto itself about the longitudinal axis W so as to block a corresponding bundle of bristles 110 and make the brush 100.

[0098] It should be noted that the machine 1 of the invention is also particularly compact and contained in size due to the first moving drum 6 around which the various operating stations 3, 4, 5 are positioned.

Claims

CLAIMS1. Machine (1) for making brushes (100) made of a metal wire (101) bent and twisted so as to clamp a bundle of bristles (110) comprising:- supply means (2) for unwinding a metal wire (101) from a reel and moving it along a feeding direction (A), in particular along a moving plane (M);- a first operating station (3) for receiving said wire (101) from said supply means (2), cutting the wire so as to create wire sections (102) of predefined length and bending each wire section (102) substantially with a “V” shape so as to obtain a bent wire section (103) having two wire portions (103a);- a second operating station (4) for associating with each bent wire section (103) a respective bundle of bristles (110);- a third operating station (5) for trimming each bundle of bristles (110) associated with each bent wire section (103); characterized by further comprising a first moving drum (6) provided with a plurality of operating units (7), each comprising respective gripping means (11, 12) and related driving means (31, 32, 33, 34, 35) arranged to receive, support and twist a bent wire section (103), said operating stations (3, 4, 5) being positioned angularly spaced about said first moving drum (6) that is rotatable with a first rotation direction (SI) about a first rotation axis (XI) orthogonal to said moving plane (M), in order to position each operating unit (7) in sequence at each of said operating stations (3, 4, 5), wherein while each operating unit (7) is moved from said second operating station (4) to said third operating station (5), the respective gripping means (11, 12) are activated for twisting said bent wire section (103) on itself about a respective longitudinal axis (W), with the bundle of bristles (110) so as to block the latter and make a brush (100),2. Machine (1) according to claim 1, wherein each operating unit (7) comprises first gripping means (11) for grasping a bent end (103b) of said bent wire section (103) and second gripping means (12) for grasping free ends (103c) of said bent wire section (103), said first gripping means (11) being operable in rotation about a torsion axis (B) by means of first driving means (31) so as to twist said wire portions (103a) of said bent wire section (103) onto each other about the respective longitudinal axis (W).

3. Machine (1) according to claim 2, wherein each operating unit (7) comprises second driving means (32) for linearly moving said second gripping means (12), in particular parallel to said torsion axis (B), for selectively grasping or releasing said free ends (103c) of said bent wire section (103).

4. Machine (1) according to one of the preceding claims, wherein each operating unit (7) comprises clamping means (24) configured to bring said wire portions (103a) closer together and into abutment with each other at said bent end (103b) so as to block a respective bundle of bristles (110) that is inserted between said wire portions (103a) in the second operating station (4), in particular said clamping means (14) being actuated by third driving means (33).

5. Machine (1) according to claim 2, wherein each operating unit (7) comprises fourth driving means (34) and fifth driving means (35) to drive respectively said first gripping means (11) and said second gripping means (12) selectively in closing or opening to block or release said bent wire section (103).

6. Machine (1) according to one of the preceding claims, wherein said first operating station (3) comprises cutting means (17) for slidably guiding said wire (101) moved along said feeding direction (A) and cutting the wire in order to make a wire section(102) of predefined length, guiding and abutment means (18) for slidably guiding said wire (100) along said feeding direction (A) and a first transfer arm (20) provided with a first end (20a) that supports a bending element (21) and third gripping means (13), said first transfer arm (20) being movable, in particular transversally to the moving plane (M), so as to push said bending element (21) against the guiding and abutment means (18) in order to bend said wire section (102) supported by them into a substantially "V" shape and form a corresponding bent wire section (103), said third gripping means (13) being operable to grasp and block said bent wire section (103).

7. Machine (1) according to claim 6, wherein said first arm (20) is further movable, in particular parallel and then orthogonal to said moving plane (M), in order to transfer said bent wire section (103), blocked by said third gripping means (13), to first gripping means (11) of an operating station (7) adjacent to said first operating station (3).

8. Machine (1) according to one of the preceding claims, wherein said second operating station (4) comprises a supply magazine (23) suitable for housing a plurality of bundles of bristles (110) and fourth gripping means (14) arranged to take one bundle of bristles (110) at a time and insert it between the two wire portions (103a) of a bent wire section(103) supported and held by the first gripping means (11) of an operating unit (7) arranged by said first moving drum (6) adjacent to said second operating station (4).

9. Machine (1) according to one of the preceding claims, wherein said third operating station (5) comprises trimming means (25, 26) defining a cutting edge (27) and selectively movable along a cutting direction (T) to approach or move away from abrush (100) supported by an operating unit (7) arranged adjacent, respectively to trim or disengage a bundle of bristles (110) of said brush (100).

10. Machine (1) according to claim 9, wherein said trimming means (25, 26) are also movable about an adjustment axis (Y) in order to change an angle (a) of said cutting edge (27) with respect to a longitudinal axis (W) of said brush (100).

11. Machine (1) according to claim 9 or 10, wherein said trimming means (25, 26) comprise a rotary cutter (25) and a counter knife (26) both cooperating to form said cutting edge (27) and interact and cut a bundle of bristles (110).

12. Machine (1) according to one of the preceding claims, wherein said first moving drum (6) is rotatable with intermittent motion about said first rotation axis (XI), in particular said first rotation axis (XI) being substantially horizontal, the gripping means (11, 12) of each operating unit (7) being actuated by the respective driving means (31, 32, 33, 34, 35) in order to twist the respective bent wire section (103) onto itself and make a brush (100) during stopping steps and / or moving steps of said intermittent motion while said first moving drum (6) is rotated so as to move said operating unit (7) from the second operating station (4) towards said third operating station (5).

13. Machine (1) according to one of the preceding claims, comprising a fourth operating station (8) for carrying out quality checks on each brush (100) in order to identify brushes (100) compliant with defined quality requirements and brushes (100) non- compliant with the quality requirements, in particular said fourth operating station (8) comprising vision means (28) configured to acquire at least one image of each brush (100) and a checking unit (50) adapted to at least of compare said detected image with a sample image.

14. Machine according to one of the preceding claims, comprising an exit station (10), wherein said brushes (100), in particular brushes (100) compliant with defined quality requirements, are taken and transferred out of the machine (1) and a reject station (9), wherein brushes (100) non-compliant with the defined quality requirements are taken and transferred out of the machine (1).

15. Machine (1) according to one of the preceding claims, comprising a second moving drum (60) positioned at the side of the first moving drum (6) and provided with a plurality of seats (61) each of which is adapted to receive and support a respective brush (100) received from the first moving drum (6), said second moving drum (60) being rotatable with a second rotation direction (S2) about a second rotation axis (X2), parallel to said first rotation axis (XI), and configured to position each brush (100) in sequenceat a fourth operating station (8), in which quality checks are carried out on said brush (100), at a reject station (9), in which said brush (100) if non-compliant with defined quality requirements is taken and transferred out of the machine (1), at an exit station (10) in which said brush (100) if compliant with said defined quality requirements is taken and transferred out of the machine (1).

16. Machine (1) according to claim 15, wherein said fourth operating station (8), said reject station (9), and said exit station (10) are positioned angularly spaced around said second moving drum (60).

17. Machine (1) according to claim 15 or 16, wherein said fourth operating station (8) comprises fifth gripping means (15) for grasping a single brush (100), extracting it from the respective seat (61) of the second moving drum (60), rotating it about the respective longitudinal axis (W) to allow vision means (28) of said fourth operating station (8) to acquire at least one image of said brush (100) and then reinserting it into said respective seat (61).

18. Machine (1) according to one of claims 15 to 17, comprising transfer means (19) positioned downstream of said third operating station (5) with reference to said first rotation direction (SI) of said first moving drum (6) about said first rotation axis (XI) and configured to pick up one brush (100) at a time from a respective operating unit (7) and then insert it into a respective seat (61) of said second moving drum (60).

19. Machine (1) according to claim 18, wherein said transfer means (19) comprise a second transfer arm (22) provided with a second end (22a) supporting sixth gripping means (16) and movable, in particular transversally and parallel to the moving plane (M), for grasping by means of said sixth gripping means (16) one brush (100) at a time from a respective operating unit (7) and then transferring, inserting and releasing said brush into a respective seat (61) of said second moving drum (60).

20. Machine (1) according to one of claims 15 to 19, wherein said reject station (9) comprises first picking means (70) arranged to take and extract one at a time from a respective seat (61) of second moving drum (60) brushes (100) non-compliant with defined quality requirements and wherein said exit station (10) comprises second picking means (80) arranged to take and extract one at a time from a respective seat (61) of second moving drum (60) brushes (100) compliant with the defined quality requirements.