Semi –automated braided sleeve cutting machine

Abstract

The present invention discloses a semi-automated machine for precision cutting and sealing of nylon braided sleeves It features a Cutter Unit (100) with a heated knife (102) at approximately 410°C for simultaneous cutting and edge sealing, preventing sleeve fraying. A servo-driven Pulling Roller (106) removes each cut segment smoothly from the cutting area. Linear Motion Blocks (LM Blocks) (108) provide guided stability, enhancing alignment and precision during feeding and cutting. The Feeding Unit with Suspension Mechanism (118) and Deadweight Clamp maintains sleeve tension and alignment. An integrated Human-Machine Interface (HMI) Display (130) and Electric Control Panel (128) allow operators to set parameters, with a Programmable Logic Controller (PLC) managing the machine's synchronized functions, including temperature, motor torque, and safety. This design ensures consistent, efficient, and reliable operation, offering enhanced accuracy and durability for sleeve processing.

Description

[0001] Title: SEMI -AUTOMATED BRAIDED SLEEVE CUTTING MACHINE FIELD OF INVENTION

[0002] The present disclosure relates to the field of mechanical engineering. The braided sleeve cutting machine is a semi -automated system specifically designed to cut braided nylon sleeves to the desired length with precision. It integrates a specially designed heated knife, which is the key element of the machine. More particularly, the present disclosure relates to a semi-automated braided sleeve cutting machine.

[0003] BACKGROUND OF THE INVENTION

[0004] The advancement of mechanical engineering has led to the development of various sophisticated and highly specialized machinery. The arena of cutting equipment, in particular, has undergone numerous transformations over the years, each innovation aimed at increasing efficiency, precision and convenience of operation. One specific subset of this broader field is the domain of braided sleeve cutting machines. These machines cater to the unique needs of cutting braided nylon sleeves, a task that requires distinct operational attributes due to the material characteristics of nylon, and the specific dimensions and neatness required in the cut pieces. The crucial element of these machines is the integration of a custom-designed heated knife, which plays a pivotal role in ensuring the desired precision and quality of the cut. The present disclosure seeks to delve into the realm of semi -automated braided sleeve cutting machines, offering a deeper perspective into their design and function.

[0005] The prior art presents various limitations in the context of sleeve cutting technology. Notably, existing systems fail to simultaneously cut and seal the edges of materials like braided nylon, which can lead to product degradation through fraying. Furthermore, the absence of automation or programmable control in many of these systems results in inconsistencies in cut lengths, particularly due to operator errors or imprecise feeding mechanisms. In any systems which employ heating elements,lack of precise temperature control can also compromise cut quality, resulting in incomplete cuts, unsealed edges, or melted material. Safety mechanisms are often lacking as well, heightening the risk of operator injury. Prior art also frequently lacks user-friendly options for adjusting settings like length, quantity, or temperature, increasing the likelihood of error and inefficiency.

[0006] Given these limitations, there exists an inherent need for a new system or technology that addresses these issues, ensuring cut precision, edge sealing capability, reliable temperature control, effective safety provisions, and user-friendly controls, while also reducing manual error and enhancing overall efficiency. This need is particularly acute when processing durable and versatile materials like braided nylon.

[0007] SUMMARY

[0008] One or more of the problems of the conventional prior art may be overcome by various embodiments of the present disclosure.

[0009] In one aspect of the present disclosure, a semi -automated braided sleeve cutting machine is configured to cut and seal nylon braided sleeves to a desired length. The machine includes a feeder unit, a servo drive unit, a knife unit with heating control, a pull-out roller to draw cut sleeve pieces away from the cutting zone after each cut, and a programmable logic controller (PLC) control unit to coordinate the operation of various machine elements.

[0010] In another aspect of the present disclosure, the roll holder unit of the feeder can support various roll sizes and allows for quick loading and unloading of rolls to enhance operational efficiency.

[0011] In another aspect of the present disclosure, the machine's dead weight clamp is adjustable to accommodate sleeves of different thicknesses, ensuring optimal tension during the feeding process.

[0012] In another aspect of the present disclosure, the polyurethane (PU) feed roller of the machine includes a high-friction surface for secure gripping, minimizing slippage and ensuring controlled movement of the sleeve.In another aspect of the present disclosure, the machine's servo motor includes a torque detection feature that stops the machine and triggers an alarm in the event of sleeve obstruction or resistance, enhancing operator safety and machine protection. In yet another aspect, the embedded heater in the knife unit of the machine is controlled by an automated temperature controller that maintains the knife temperature within a range of ±5°C of the target temperature to ensure consistent cutting quality.

[0013] In another aspect of the present disclosure, the pneumatic actuator lowers the knife onto the sleeve in response to a signal from the PLC control unit, applying a controlled downward force on the heated knife for a precise cut and sealed edges. In another aspect of the present disclosure, the PLC control unit of the machine includes safety interlocks and sensors configured to retract the knife in case of unintended operator proximity, ensuring safe machine operation.

[0014] Yet, another aspect of the present disclosure involves the HMI display of the PLC control unit which is configured to store multiple cutting length and quantity parameters as pre-set recipes.

[0015] In another aspect of the present disclosure, the disclosed device further includes an emergency stop button accessible to the operator, enabling immediate halting of the machine operation in case of an emergency.

[0016] In another aspect of the present disclosure, the machine generates an audible or visual alarm to indicate the completion of a cutting cycle, allowing the operator to retrieve cut pieces or input new parameters.

[0017] DETAILED DESCRIPTION OF THE DRAWINGS

[0018] Fig 1 illustrates Cutter Unit with heater control in accordance with the present invention

[0019] Fig 2 illustrates the pulling roller configuration in accordance with the present invention

[0020] Fig 3 illustrates linear motion Blocks and their components in accordance with the present invention

[0021] Fig 4 illustrates the machine responsible for feeding unit with suspension of the braided sleeve cutting machine in accordance with the present inventionFig 5 illustrates the Human-Machine Interface (HMI) display and the electric control panel of the braided sleeve cutting machine in accordance with the present invention.

[0022] Fig 6 illustrates the semi -automated braided sleeve cutting machine in accordance with the present invention.

[0023] Fig 7 illustrates the perspective view of the Cutter Unit with heater control in accordance with the present invention

[0024] Fig 8 illustrates the perspective view of poly urethane feeding unit with servo motor

[0025]

[0026] DETAILED DESCRIPTION OF THE PREFERRE EMBODIMENTS

[0027] In one embodiment of the present invention, a semi -automated braided sleeve cutting machine is designed to accurately cut and seal nylon braided sleeves to a desired length. This embodiment includes a feeder unit which comprises a roll holder unit aimed to securely hold a roll of nylon braided sleeve, facilitating free rotation as the sleeve is inserted into the machine. To maintain the alignment of the sleeve and avoid tangling, a path segregator is integrated. Furthermore, to maintain consistent tension on the sleeve during feeding, preventing deviations in the cutting process, a dead weight clamp has been configured.

[0028] Crucial to the feeding process, a polyurethane (PU) feed roller unit is included where the PU feed roller has been devised with a spring-loaded mechanism applying consistent pressure on the sleeve, warranting smooth and precise movement into a cutting area. The movement and position of the sleeve are precisely controlled by a servo motor, which is part of a servo drive unit operationally connected to the feeder unit. The PU feed roller's motion is enabled and synchronized with the servo motor through a driven timing pulley emotionally connected via a timing belt to a drive timing pulley coupled to the servo motor, ensuring a levels and controlled feeding of the sleeve.

[0029] This embodiment also includes a knife unit with heating control capability. At a stipulated cutting temperature of approximately 410°C, a heated knife is designed to cautiously cut and seal the nylon braided sleeve, where the heated knife counteracts fraying by melting and sealing the edges of the sleeve. For precise alignment of the knife along the cutting axis, a guide unit is also incorporated. Also included, a pneumatically driven actuator is designed to lower the knife onto the sleeve when it receives a signal, enabling controlled cutting pressure.

[0030] At the completion of each cut, a pull-out roller is strategically positioned downstream from the cutting area, this function of this roller is to draw the cut sleeve piece away from the cutting zone, ensuring clean separation.

[0031] To orchestrate the operation of the machine components according to the input parameters, and to monitor and control the cutting temperature, motor torque, and cutting speed to ensure consistent, precise cutting and sealing of the sleeve, aprogrammable logic controller (PLC) control unit is operationally linked to the feeder unit, servo drive unit, knife unit, and pull-out roller. Inputs regarding cutting length and quantity parameters are received and processed by the PLC control unit via a human-machine interface (HMI) display.

[0032] Fig. 1 illustrates the Cutter Unit (100) with heater control in accordance with the present invention. The Cutter Unit (100) comprises a precisely designed heated blade (102) configured to reach a controlled temperature of approximately 410°C, which is crucial for both cutting and sealing the edges of nylon braided sleeves. This configuration prevents fraying by ensuring the edges are sealed immediately upon cutting. The heating coil (104) embedded within the blade maintains the target temperature with automated control, optimizing the cutting process for consistent results and enhancing the durability of the cuts. Additionally, the cutter unit (100) includes safety mechanisms that retract the blade (102) when not in operation, ensuring a safe environment for the operator.

[0033] Fig. 2 shows the configuration of the Pulling Roller (106), essential to the machine’s post-cutting mechanism. This roller operates synchronously with the cutter unit (100), pulling the cut segment away from the cutting area once the sleeve is severed. The roller (106) is servo-driven, providing precise and consistent traction to guide each sleeve piece smoothly out of the cutting zone, thereby minimizing the potential for obstruction or overlapping. The design of the pulling roller allows for controlled extraction, ensuring each segment is handled with accuracy and ease, ready for further processing or collection.

[0034] Fig. 3 depicts the Linear Motion Blocks (LM Blocks) (114) and their associated components, which facilitate the guided, stable movement of the machine's parts along designated paths. These LM Blocks (114) are crucial for aligning and supporting the movement of both the feeding unit (118) and cutting unit (112), reducing friction, and ensuring smooth motion. The arrangement allows for accurate positioning of the sleeve during feeding and cutting operations, contributing to the precision and reliability of the machine’s functions. The LM Blocks (114) are integrated with a motor (116) to enhance the linearity and stability of the machine’s processes.Fig. 4 illustrates the machine’s Feeding Unit (118) equipped with a Suspension Mechanism (124), responsible for guiding the braided sleeve material into the cutting area with controlled tension and alignment. This feeding unit (118) includes mechanisms such as the Roll Holder (110), Path Segregator, and Deadweight Clamp (120), each contributing to maintaining the sleeve’s stability during the feeding process. The suspension mechanism (124) ensures the sleeve remains taut and properly aligned, preventing deviations that could affect cutting accuracy. The system’s design reduces resistance, allowing for efficient material feed into the cutting unit (112).

[0035] Fig. 5 demonstrates the Human-Machine Interface (HMI) Display (130) and the Electric Control Panel (128) of the braided sleeve cutting machine. The HMI (130) allows the operator to input parameters such as desired cutting length and quantity, streamlining the operation with automated controls and precision. The control panel (128) manages the machine’s functions, coordinating the various components to operate in a synchronized sequence. This panel includes the Programmable Logic Controller (PLC) and other essential electronic elements that oversee safety measures, temperature controls, and real-time adjustments, ensuring optimal machine performance and operator safety.

[0036] The present invention relates to a semi -automated braided sleeve cutting machine that comprises a servo drive unit operatively connected to a feeder unit (118). The servo drive unit includes a servo motor (116) configured to control the movement and position of the sleeve with high precision. The drive timing pulley (122) is coupled to the servo motor (116) for transmitting rotational motion, and a timing belt (122) is operably connected between the drive timing pulley and a driven timing pulley. The driven timing pulley is connected to the PU feed roller (106), enabling synchronized movement with the servo motor (116) for controlled feeding of the sleeve.

[0037] The invention further comprises a knife unit (100) with heating control, wherein the knife unit includes a heated knife (102) adapted to cut and seal the nylon braided sleeve at a controlled temperature of approximately 410°C. The heated knife (102) prevents fraying by melting and sealing the edges of the sleeve. Additionally, theknife (102) is equipped with a heating coil (104) embedded within it to maintain the desired cutting temperature through an automated temperature control system. A guide unit (114) ensures precise alignment of the knife (102) along the cutting axis.

[0038] The invention includes a bottom cutting fixture (112) with a V-shaped notch, which is designed to support the sleeve during cutting and facilitate edge sealing. A pneumatic actuator (126) is configured to lower the knife (102) onto the sleeve upon receiving a signal, thereby enabling controlled cutting pressure. A pull-out roller (106) is positioned downstream from the cutting area and configured to draw the cut sleeve piece away from the cutting zone after each cut, ensuring a clean separation.

[0039] A programmable logic controller (PLC) control unit is operatively connected to the feeder unit (118), servo drive unit, knife unit (100), and pull-out roller (106). The PLC control unit is configured to receive and process input parameters, including cutting length and quantity, via a human-machine interface (HMI) display (128). It coordinates the operation of the machine components according to the input parameters, executing the cutting cycle based on the set length and quantity.

[0040] The PLC control unit monitors and controls various operational parameters, including cutting temperature, motor torque, and cutting speed, ensuring consistent and precise cutting and sealing of the sleeve. This control ensures that the sleeve cutting process is executed with accuracy and reliability.

[0041] The roll holder unit (110) of the machine is configured to support various roll sizes, enabling quick loading and unloading of rolls, thereby enhancing the operational efficiency of the machine. This configuration allows the machine to handle different sleeve materials without requiring extensive manual adjustments.

[0042] The machine further includes a dead weight clamp (120), which is adjustable to accommodate sleeves of varying thicknesses. The dead weight clamp (120) ensures optimal tension during the feeding process, thus maintaining sleeve alignment and preventing slippage that could compromise the quality of the cut.

[0043] The PU feed roller (106) within the system features a high-friction surface, which provides secure gripping of the sleeve. This minimizes slippage and allows forprecise and controlled movement of the sleeve, contributing to the overall accuracy of the cutting process.

[0044] From Fig 8, the perspective view of poly urethane feeding unit with servo motor is shown where the servo motor (116) incorporated in the machine includes a torque detection feature, which stops the machine and triggers an alarm in the event of sleeve obstruction or resistance. This feature enhances operator safety and protects the machine from potential damage due to mechanical stress.

[0045] The heating coil (104) embedded within the knife (102) is controlled by an automated temperature controller that maintains the knife temperature within a range of ±5°C of the target temperature. This precise temperature control ensures consistent cutting quality by preventing overheating or underheating during the cutting process.

[0046] The pneumatic actuator (126) operates in response to a signal from the PLC control unit, applying a controlled downward force on the heated knife (102) to achieve a precise cut and sealed edges. The invention includes safety interlocks and sensors configured to retract the knife (102) in case of unintended operator proximity, ensuring safe operation of the machine. The HMI display (130) is configured to store multiple cutting length and quantity parameters as pre-set recipes, allowing for quick retrieval and setup for repeated cutting tasks. An emergency stop button accessible to the operator enables immediate halting of machine operation in case of emergency, and the machine generates an audible or visual alarm upon completion of a cutting cycle, signalling the operator to retrieve cut pieces or input new parameters.

[0047] In Fig 7, the nylon sleeve cutting machine is equipped with a heated hot knife / cutter (102) that is powered by a heater coil (104 ) system, enabling the sealing of the nylon sleeve ends during the cutting process. The specially designed hot knife / cutter (102) is engineered to prevent fraying of the nylon string. It is capable of withstanding temperatures up to 400°C, with the temperature being adjustable to meet the specific requirements of the material being cut.

[0048] Fig 8 illustrates the perspective view of poly urethane feeding unit with servo motor where the machine is equipped with an automatic feeding system that draws nylonsleeves from a spool and advances them to the cutting station. The feeding process is controlled by a servo motor (116), ensuring precise dimensioning and accurate material feed.

[0049] From Fig 6 a semi-automated braided sleeve cutting machine designed for precision cutting and sealing of nylon braided sleeves. The machine integrates a Cutter Unit (100) equipped with a heated knife (102) and heating coil (104) capable of reaching 410°C to simultaneously cut and seal sleeve edges, preventing fraying. To ensure operator safety, the knife retracts when inactive, and a safety mechanism monitors temperature control. A servo-driven Pulling Roller (106) removes cut segments from the cutting area, ensuring smooth separation for further processing. The Linear Motion Blocks (LM Blocks) (114) with a motor (116) enable precise, guided movement of the feeding (118) and cutting units (112), ensuring stable and frictionless operation. The Feeding Unit (118), equipped with a Suspension Mechanism (124), includes components like the Roll Holder (110), Path Segregator, and Deadweight Clamp (120) to maintain sleeve alignment and tension, enhancing cutting accuracy. Additionally, the Human-Machine Interface (HMI) Display (130) and Electric Control Panel (128) allow operators to set parameters such as cutting length and quantity. The control panel integrates a Programmable Logic Controller (PLC) to synchronize machine functions, monitor temperature, control motor torque, and ensure efficient, safe operation, thereby streamlining the cutting process with high precision and reliability.

Claims

CLAIMS1. A semi-automated braided sleeve cutting machine, comprising:• a servo drive unit operatively connected to a feeder unit (118), wherein the servo drive unit comprises:o a servo motor (116) configured to control the movement and position of the sleeve with high precision;o a drive timing pulley (122) coupled to the servo motor (116) for transmitting rotational motion;o a timing belt (122) operably connected between the drive timing pulley and a driven timing pulley;o a driven timing pulley connected to the pu feed roller (106), enabling synchronized movement with the servo motor (116) for controlled feeding of the sleeve;• a knife unit (100) with heating control, wherein the knife unit comprises:o a heated knife (102) adapted to cut and seal the nylon braided sleeve at a controlled temperature of approximately 410°c, wherein the heated knife (102) prevents fraying by melting and sealing the edges of the sleeve;o a heating coil (104) embedded within the knife (102) to maintain the desired cutting temperature with an automated temperature control system;o a guide unit (114) configured to ensure precise alignment of the knife (102) along the cutting axis;o a bottom cutting fixture (112) with a v-shaped notch designed to support the sleeve during cutting and facilitate edge sealing;o a pneumatic actuator (126) configured to lower the knife (102) onto the sleeve upon receiving a signal, enabling controlled cutting pressure;o a pull-out roller (106) positioned downstream from the cutting area, configured to draw the cut sleeve piece away from the cutting zone after each cut, thereby ensuring clean separation;• a programmable logic controller (pic) control unit operatively connected to the feeder unit (118), servo drive unit, knife unit (100), and pull-out roller (106), the pic control unit configured to:o receive and process input parameters, including cutting length and quantity, via a human-machine interface (hmi) display (128); o coordinate the operation of the machine components according to the input parameters, executing the cutting cycle based on the set length and quantity;o monitor and control the cutting temperature, motor torque, and cutting speed to ensure consistent, precise cutting and sealing of the sleeve.

2. The semi -automated braided sleeve cutting machine as claimed in claim 1, wherein the roll holder unit (110) is configured to support various roll sizes and allows for quick loading and unloading of rolls to enhance operational efficiency.

3. The semi -automated braided sleeve cutting machine as claimed in claim 1, wherein the dead weight clamp (120) is adjustable to accommodate sleeves of different thicknesses, ensuring optimal tension during the feeding process.

4. The semi -automated braided sleeve cutting machine as claimed in claim 1, wherein the PU feed roller (106) includes a high-friction surface for secure gripping, minimizing slippage and ensuring controlled movement of the sleeve.

5. The semi -automated braided sleeve cutting machine as claimed in claim 1, wherein the servo motor (116) includes a torque detection feature that stops the machine and triggers an alarm in the event of sleeve obstruction or resistance, enhancing operator safety and machine protection.

6. The semi -automated braided sleeve cutting machine as claimed in claim 1, wherein the heating coil (104) embedded within the knife (102) is controlled by an automated temperature controller that maintains the knife temperaturewithin a range of ±5°C of the target temperature to ensure consistent cutting quality.

7. The semi -automated braided sleeve cutting machine as claimed in claim 1, wherein the pneumatic actuator (126) operates in response to a signal from the PLC control unit, applying a controlled downward force on the heated knife (102) for a precise cut and sealed edges.

8. The semi -automated braided sleeve cutting machine as claimed in claim 1, wherein the PLC control unit includes safety interlocks and sensors configured to retract the knife (102) in case of unintended operator proximity, ensuring safe machine operation.

9. The semi -automated braided sleeve cutting machine as claimed in claim 1, wherein the HMI display (130) is configured to store multiple cutting length and quantity parameters as pre-set recipes, allowing for quick retrieval and setup for repeated cutting tasks.

10. The semi -automated braided sleeve cutting machine as claimed in claim 1, further comprising an emergency stop button accessible to the operator, enabling immediate halting of the machine operation in case of an emergency.

11. The semi -automated braided sleeve cutting machine as claimed in claim 1, wherein the machine generates an audible or visual alarm to indicate the completion of a cutting cycle, allowing the operator to retrieve cut pieces or input new parameters.

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