Needle Separating Device with Integrated Ejection

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Solution Overview

Problem

Existing needle separation devices for needle boards in nonwoven fabric or needle felt production are either costly due to the need for multiple components and space or inefficient due to reliance on image processing and robots, which are slow and have low hit ratios.

Innovation Solution

A device with a receiving element and integrated ejection mechanism that positions needles through a through opening, allowing for precise and efficient separation without the need for separate conveyor units or complex image processing, enabling quick and reliable needle placement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If multiple conveyor units are used for needle separation, then needle separation function is achieved, but device complexity and space requirements increase

Engineering Contradiction:

Improvenumber of conveyor unitsVSAvoidspace occupied by separation device

Core Design Contradiction:

Device complexityVSArea of stationary object

Solution Approach 1:

The patent combines the oscillating conveyor and belt conveyor into a single integrated conveyor unit. The oscillating conveyor has a receiving element that directly interfaces with the belt conveyor, eliminating the need for separate conveyor units. This merging reduces device complexity and space occupation while maintaining the needle separation function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single conveyor unit performs multiple functions: it receives needles, separates them through oscillating motion, and transports them to the needle board. The receiving element on the oscillating conveyor serves both as a needle storage area and as a separation mechanism, demonstrating multi-functionality that reduces overall device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Extent of automation

If robot with image detection is used for needle pickup, then automation is achieved, but processing time increases significantly

Engineering Contradiction:

Improveneedle pickup automationVSAvoidtime for needle detection and pickup

Core Design Contradiction:

Extent of automationVSLoss of time

Solution Approach 1:

The oscillating conveyor pre-separates and orients needles in a defined direction before the needle pickup operation. This preliminary organization of needles eliminates the need for complex image detection and positioning algorithms, allowing for faster automated pickup without sacrificing accuracy.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The oscillating conveyor automatically orients needles with crutches in the same direction through its mechanical oscillating motion, without requiring external detection systems. The system self-organizes the needles, eliminating time-consuming image processing and computational positioning.

Inventive Principle:

Principle #25Self-service

3Measurement precision

If high-resolution image detection is used for needle position detection, then pickup accuracy is improved, but cost and processing time increase

Engineering Contradiction:

Improveneedle position detection accuracyVSAvoidtime for image processing

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces optical/image detection systems with a mechanical oscillating conveyor system that physically orients needles. The mechanical oscillation naturally aligns needles in a defined direction, providing accurate positioning without requiring costly and time-consuming high-resolution image detection and processing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS9963811B2Device for separating needles

Publication Date: 2018.05.08 AUTEFA SOLUTIONS GERMANY GMBH

AI summary

A device for separating needles (1) includes a receiving element (2) for needles (1) and a separating device (3). The receiving element (2) includes at least one through opening (4). The separating device (3) includes an ejection device (5) which can be passed through the through-opening (4) of the receiving element (2). The ejection device (5) has a contact area (6) on the upper edge which corresponds at least to a needle (1) and detects the needle.