Cleaning Brush Positioning With Image Feedback in Fabric Finishing
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Solution Overview
Problem
Manual positioning and adjustment of cleaning brushes in teaseling machines are laborious, imprecise, and time-consuming, requiring specialized manpower and frequent adjustments due to wear, which limits productivity.
Innovation Solution
An automatic positioning and adjusting device using image acquisition and control means to precisely determine and adjust the distance between cleaning brush fibers and chocks, employing an electric motor with a worm screw mechanism and a user interface for remote operation, allowing for real-time, precise positioning without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual positioning and adjustment of cleaning brushes is used, then the device structure remains simple, but the adjustment process becomes laborious, imprecise, and time-consuming
Solution Approach 1:
The patent replaces the manual mechanical positioning system with an automated system comprising image acquisition means (camera), control means (processor), and movement means (motor with worm screw mechanism). The system automatically captures images of the brush and chock positions, processes these images to determine distances, and actuates the motor to position the brush fibers at the desired distance from chock ends, eliminating manual measurement and adjustment operations.
Solution Approach 2:
The system enables self-service positioning by automatically measuring the distance between brush fibers and chock ends using image acquisition, processing this data to determine the exact positioning required, and actuating the movement mechanism without operator intervention. The control system autonomously manages the entire positioning process from measurement to execution.
2Manufacturing precision
If manual positioning and adjustment of cleaning brushes is used, then the device complexity remains low, but the manufacturing precision and measurement accuracy deteriorate
Solution Approach 1:
The patent replaces imprecise manual measurement methods with an optical measurement system using image acquisition means. The camera captures images of the brush and chock positions, and the control means processes these images to calculate exact distances with high precision, eliminating the inaccuracies inherent in manual measurement while accepting the increased system complexity.
Solution Approach 2:
The patent introduces image acquisition means and control means as intermediary components between the operator and the positioning process. These intermediaries automatically perform the measurement and calculation functions, providing precise positioning data without requiring the operator to directly measure and calculate distances, thereby improving precision despite added complexity.
3Productivity
If manual positioning and adjustment of cleaning brushes is used, then the device structure remains simple, but the productivity deteriorates due to frequent stoppages
Solution Approach 1:
The patent enables continuous operation by allowing brush positioning adjustments to be made while the machine operates or with minimal interruption. The automated system can quickly measure and adjust brush positions without requiring prolonged stoppages, maintaining continuous productive action compared to manual adjustment methods that necessitate extended machine stoppages.
Solution Approach 2:
The patent replaces time-consuming manual adjustment operations with an automated motor-driven positioning system that can rapidly adjust brush positions. This substitution dramatically reduces the time required for adjustments, minimizing productivity loss and allowing the machine to maintain higher operational efficiency despite the added system complexity.
4Reliability
If manual positioning and adjustment of cleaning brushes is used, then the device remains simple to operate, but the reliability deteriorates due to wear requiring frequent adjustments
Solution Approach 1:
The patent implements a feedback mechanism where image acquisition means continuously or periodically monitor the position of brush fibers relative to chock ends. The control means processes these images to determine current distances and compares them against desired positioning parameters, automatically actuating the motor to correct any deviations. This closed-loop feedback system maintains reliable positioning despite fiber wear, eliminating the need for frequent manual adjustments.
Solution Approach 2:
The system performs self-service positioning by automatically detecting and correcting brush position deviations caused by wear. The image acquisition and control systems continuously monitor and adjust brush positions without operator intervention, maintaining reliable operation throughout the brush service life and eliminating the recurring manual adjustment tasks required by simpler systems.
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 solution enables quick, precise, and automatic adjustment of cleaning brushes, reducing labor and downtime, maintaining efficiency despite wear, and eliminating the need for frequent manual adjustments.
Implementation Method 1
means for the acquisition of images, which are disposed in proximity to the at least one cleaning brush and are suitable to acquire images of the zone of proximity and/or contact between the ends of the fibers and the ends of the needles
Implementation Method 2
movement means which are commanded by the control means and are suitable to move the cleaning brush toward the needles of the chocks
Data Source
Figure 1
Figure 2a~2b
Figure 3~4
AI summary
Positioning and adjusting device for at least a cleaning brush (37) of a fabric finishing machine such as a teaseling machine (11), a fluffing machine or similar, which comprises a plurality of rotating chocks (23) having needles (25) or pointed protuberances. The cleaning brush (37) comprises a plurality of fibers (39) or filaments suitable to remove, during use, possible residues of fabric or other types of residue from the chocks (23). The device comprises image acquisition means (51), disposed in proximity to the cleaning brush (37) and suitable to acquire images of the zone of proximity and/or contact between the ends of the fibers (39) and the ends of the needles (25) in order to find the distance (D1, D2, D3) between the latter.