Brush Filling Force Sensing With Overload-Relief Lever
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Solution Overview
Problem
Existing brush stuffing machines are prone to damage due to excessive stuffing forces, which can lead to breakdowns and failures, and existing monitoring systems are inadequate in preventing such damage.
Innovation Solution
A brush stuffing machine equipped with a force sensor pre-tensioned to measure the stuffing force, using a power transmission lever to relieve the sensor of stress when an overload is detected, thereby protecting the sensor and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a force sensor is installed to monitor stuffing force, then damage to the brush stuffing machine can be prevented, but the force sensor itself is vulnerable to damage from excessive stuffing forces
Solution Approach 1:
The force sensor is installed in reverse orientation so that the normal stuffing force compresses the sensor within its measurement range, while excessive force relieves the sensor of stress by moving the power transmission lever away from the sensor. This inversion allows the sensor to function as both a measurement device and an overload protection device.
Solution Approach 2:
The power transmission lever is designed to be movable relative to the force sensor, allowing the system to dynamically adapt to varying stuffing forces. Under normal conditions, the lever maintains contact with the sensor for measurement; under overload conditions, the lever moves away from the sensor to prevent damage.
2Productivity
If the stuffing force is increased to improve stuffing efficiency, then productivity increases, but the risk of breaking the ram tongue or damaging the drive increases
Solution Approach 1:
The force sensor provides real-time feedback on the stuffing force acting on the ram tongue. This feedback allows the control system to monitor the force levels and take protective actions when the force approaches dangerous levels, preventing breakage of the ram tongue or damage to the drive while allowing high stuffing forces to be applied for improved productivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively prevents damage to the force sensor and other components by detecting and responding to excessive stuffing forces, ensuring reliable operation and extending the machine's lifespan.
Implementation Method 1
a force sensor pre-tensioned with a pre-tension force in its initial position, against which the power transmission lever is biased in the stuffing direction, to determine a stuffing force acting on the ramming tongue by means of a resulting force from the pre-tension force and the stuffing force
Data Source
Figure 1
Figure 2
AI summary
The invention relates, inter alia, to a brush filling machine (1) comprising a filling tool (2) which has a rammer tongue (3) designed to fill bristle bundles (4) into bundle receiving holes (5) in a brush body (6), wherein the brush filling machine (1) has a force sensor (10) which is preloaded with a preloading force (24) in the starting position and which is designed to measure a force resulting from a filling force (25) acting on the rammer tongue (3) when filling bristle bundles (4) and from the preloading force (24) applied to the force sensor (10) in the starting position.