Cleaning Member Fiber Bundle Twisting Correction via Non-Rotational Bars
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Solution Overview
Problem
The existing methods for manufacturing cleaning members with opened fiber bundles face challenges in correcting twisting of the fiber bundle during the feeding path from the storage container to the driving roller and stabilizing the manufacturing process, as well as speeding up the opening process from the driving roller to the opening step.
Innovation Solution
A method and apparatus that involves winding the fiber bundle onto non-rotational bars to change its feeding direction, applying different tensions to correct twisting, and using multiple driving rollers to pre-open the fiber bundle, ensuring it is fed in intersecting directions to stabilize and expedite the opening process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fiber bundle is fed directly from the storage container to the driving roller, then the device complexity is reduced, but the fiber bundle twisting cannot be corrected and the manufacturing process becomes unstable
Solution Approach 1:
A guide roller is introduced as an intermediary component between the storage container and the driving roller. This guide roller serves as a mediator that redirects the fiber bundle feeding path, enabling twisting correction without requiring complex active control systems. The guide roller's strategic positioning allows it to naturally correct twists through passive mechanical guidance.
Solution Approach 2:
The fiber bundle feeding path is extended into a three-dimensional configuration by introducing the guide roller at a different spatial location and orientation. This dimensional change in the feeding path allows the fiber bundle to undergo natural untwisting through the altered routing geometry, transforming a two-dimensional planar feed into a three-dimensional path that inherently corrects twists.
2Productivity
If the fiber bundle is opened directly after the driving roller, then the process time is reduced, but the opening efficiency is low due to twisted fibers
Solution Approach 1:
The guide roller performs a preliminary action of twisting correction on the fiber bundle before it reaches the opening mechanism. By pre-correcting the twists in the feeding path, the fiber bundle is prepared in advance for efficient opening, eliminating the need for subsequent twisting correction steps and enabling the opening process to proceed at maximum speed immediately.
Solution Approach 2:
The natural twisting that occurs during fiber bundle storage and feeding is converted into a beneficial pre-opening state. The guide roller utilizes the fiber bundle's inherent properties and the feeding motion itself to achieve twisting correction, transforming what was previously a harmful effect (twisting) into a useful pre-processing action that facilitates faster opening.
3Reliability
If multiple guide rollers and complex feeding paths are used to correct twisting, then the manufacturing process stability is improved, but the device complexity increases significantly
Solution Approach 1:
The twisting correction function is extracted from the main driving roller system and assigned to a separate, simple guide roller. This extraction allows the guide roller to be optimized solely for twisting correction without the complexity of drive mechanisms, while the driving roller maintains its primary function of fiber bundle transport and opening activation.
Solution Approach 2:
The guide roller is designed as a simple, inexpensive component that can be easily replaced or adjusted. Rather than investing in a complex, expensive active twisting control system with sensors and actuators, the invention uses a straightforward mechanical guide roller that achieves twisting correction through its geometry and positioning, prioritizing simplicity and ease of maintenance.
Data Source
AI summary
In a method for manufacturing a cleaning member comprising opened fiber bundle, in order to correct twisting of fiber bundle in the path for feeding the fiber bundle from a storage container to a driving roller to thereby stabilize manufacturing process, and in order to pre-open the fiber bundle in the path from a driving roller to the opening step to thereby speed-up the opening step, fiber bundle drawn out continuously from a storage container in a first direction is wound onto a non-rotational bar, and after being fed in a second direction, is fed to a first driving roller, and the fiber bundle fed from the first driving roller in a third direction is wound onto a second non-rotational bar, and after being fed in a fourth direction, is fed to a second driving roller and to the following opening step.