Bristle Pack Buffer for Brush Stuffing Machine
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Solution Overview
Problem
Existing methods for filling fiber boxes with bristle packs in brush tamping machines are complex and costly, requiring manual or semi-automatic removal of pack wrapping, which complicates the process and necessitates frequent refilling due to high cycle rates.
Innovation Solution
A method involving a separate buffer with refillable receptacles for bristle packs without pack wrapping, using a mechanical transport device to transfer bristle packs directly into fiber channels, simplifying the process and reducing the need for constant refilling by utilizing a single transport device for multiple fiber channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual or semi-automatic removal of pack wrapping is used, then the process can handle bristle packs with wrapping, but the operational complexity and costs increase
Solution Approach 1:
The pack wrapping is removed in advance before the bristle packs are inserted into the receptacles. This preliminary action eliminates the need for complex automatic unwrapping mechanisms during the high-speed filling process, thereby reducing device complexity while maintaining ease of operation.
Solution Approach 2:
The filling process is segmented into distinct steps: wrapping removal is performed separately before insertion, and the intermediate storage unit is divided into multiple receptacles. This segmentation allows each component to be optimized independently, reducing overall system complexity.
2Device complexity
If a single transport device is used for multiple fiber channels, then the device complexity is reduced, but the productivity may be limited by the refilling frequency
Solution Approach 1:
Multiple bristle packs are prepared in advance and stored in separate receptacles within the intermediate storage unit. This preliminary preparation allows the single transport device to operate continuously without frequent interruptions for refilling, thereby maintaining high productivity while using simpler equipment.
Solution Approach 2:
The intermediate storage unit with multiple receptacles acts as an intermediary between the operator and the transport device. It buffers the bristle packs, allowing the transport device to maintain a steady supply to multiple fiber channels without requiring frequent manual intervention.
3Adaptability or versatility
If bristle packs are stored in an intermediate storage unit with multiple receptacles, then the storage flexibility and distribution efficiency are improved, but the device complexity increases
Solution Approach 1:
The intermediate storage unit with multiple receptacles serves multiple functions: it stores different types of bristle packs, organizes them for different fiber channels, and provides a buffer for continuous operation. This multi-functionality increases adaptability while the modular design keeps the added complexity manageable.
4Productivity
If the bundle separator operates at high speeds (1000+ rpm), then the productivity increases, but the need for frequent refilling increases operational complexity
Solution Approach 1:
Multiple bristle packs are prepared and loaded into the intermediate storage unit in advance, creating a buffer that supports high-speed operation. This preliminary action ensures that the bundle separator can maintain speeds of 1000+ rpm without frequent interruptions for refilling, thereby maintaining ease of operation.
Solution Approach 2:
The intermediate storage unit with multiple receptacles enables continuous supply of bristle packs to the transport device, which in turn continuously feeds the bundle separator. This continuity of useful action eliminates interruptions during high-speed operation, maintaining both productivity and ease of operation.
Data Source
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AI summary
A method for filling a fibre container of a cluster separator of a brush-stuffing machine makes provision for the packs of bristles, following prior removal of the pack wrapping, to be inserted into one of a number of mounts (42) in an interim store (32). The bristle packs (44, 46) are transferred out of the mounts (42) into the appropriate fibre channel (14, 16) by means of a mechanical transporting device (50). The invention also presents a cluster separator.