Brush-stuffing machine non-linear tufting tool path
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Solution Overview
Problem
Brush tufting machines face challenges in operating smoothly at higher speeds due to increased noise and wear, as existing technologies require active movement of anchors into bundle pick-up positions, leading to inefficiencies and vibrations.
Innovation Solution
The introduction of a curved, non-linear path for the tufting tool allows the intermediate section to move under a stationary anchor, positioning the feed channel under the anchor, enabling the tamping tool to make the feed movement, thus keeping the anchor stationary and reducing additional movement requirements, along with the use of processing units like bending or cutting devices that remain fixed, allowing for shorter infeed paths and reduced mass movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the anchor is actively moved into the bundle pick-up position using existing feeding mechanisms, then the anchor can be positioned for stuffing, but the machine experiences increased noise, vibration, and wear at high speeds
Solution Approach 1:
Instead of actively moving the anchor into the bundle pick-up position, the invention inverts the approach by allowing the tufting tool to move along a curved path that passes under the stationary anchor, enabling the tool to pick up the anchor during its return stroke. This eliminates the need for separate active anchor feeding mechanisms, thereby reducing noise and vibration while maintaining high cycle rates
2Device complexity
If the tufting tool moves along a straight linear path, then the mechanism is simpler, but the anchor cannot be efficiently picked up without active feeding
Solution Approach 1:
The invention employs a curved, non-linear path for the tufting tool instead of a straight linear path. This curved trajectory allows the tool to naturally pass under the stationary anchor during its return stroke, enabling efficient anchor pickup without complex active feeding mechanisms. The curvature of the path is specifically designed to optimize the timing and position for anchor acquisition while maintaining stuffing efficiency
3Productivity
If high speeds are used to increase productivity, then more bundles can be stuffed per minute, but noise and wear increase significantly
Solution Approach 1:
The tufting tool performs dual functions during its reciprocating motion: it both stuffs bundles during the forward stroke and picks up anchors during the return stroke by passing under the stationary anchor. This self-service approach eliminates the need for separate active anchor feeding mechanisms, allowing high-speed operation with reduced mechanical complexity, noise, and wear
Data Source
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AI summary
A brush-stuffing machine comprises a stuffing tool (12) having a tip (34) and an intermediate portion (36), which bears the tip (34). The stuffing tool is moved back and forth along a non-linear path. During the rearward movement of the stuffing tool (12), an anchor, already located in its receiving position, is retained in a stationary manner while the intermediate portion (36) is moved towards the anchor and receives the anchor in a feeding channel (42). Fig. 2