Round Brush Production Apparatus with Deflecting Rollers
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Solution Overview
Problem
Existing methods for producing round brushes with bristles twisted between two portions of wire are complex, especially for larger brushes, as they require multiple working stations and manual handling, which is unsafe and limited to smaller sizes due to centrifugal forces causing the covering material to be flung away.
Innovation Solution
An apparatus with a deflecting device, a linearly displaceable rotary gripper, and a bristle feeding device allows for wire folding and bristle covering at a single station, using deflecting rollers and slowing rollers to maintain tension and prevent bristle loss, enabling coverage up to the brush's end without operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple working stations are used for wire folding and bristle feeding, then the brush production can be completed, but the apparatus complexity increases significantly
Solution Approach 1:
The patent combines wire folding and bristle feeding operations into a single working station. The deflecting device folds the wire while the bristle feeding device simultaneously feeds bristles to the folded wire portions, eliminating the need for separate stations for each operation.
Solution Approach 2:
The wire is folded into U-shaped portions before the bristle feeding process begins. This preliminary folding creates the necessary structure for bristle insertion, allowing both operations to occur at the same station without requiring sequential processing at different locations.
2Reliability
If manual handling is used to hold covering material during twisting, then bristle coverage can be maintained, but operator safety is compromised and expertise is required
Solution Approach 1:
The apparatus automatically holds the covering material between the folded wire portions using the deflecting device and rotary gripper mechanism. The system self-regulates the bristle coverage without requiring manual intervention, eliminating operator exposure to dangerous rotating components.
Solution Approach 2:
The rotary gripper acts as an intermediary mechanism that automatically clamps and releases the covering material. It mediates between the bristle feeding process and the twisting operation, ensuring continuous coverage without manual handling.
3Productivity
If centrifugal forces act during twisting of larger brushes, then the twisting process can be completed, but the covering material is flung away
Solution Approach 1:
The wire is folded into U-shaped portions before the twisting process begins. This preliminary folding creates a secure clamp structure that holds the bristles in place during the subsequent twisting operation, preventing them from being flung away by centrifugal forces.
Solution Approach 2:
The folded wire portions act as an intermediary structure that secures the covering material during twisting. The deflecting device and rotary gripper work together to maintain this securing function throughout the twisting process, preventing material loss.
4Extent of automation
If two separate portions of wire are fed, then automatic twisting is possible, but both ends of the brush must be worked and distance is needed between brush head and bristle covering
Solution Approach 1:
A single wire is segmented into multiple U-shaped portions through the deflecting device. This segmentation creates multiple gripping points and folding sections along the wire, enabling automatic twisting while allowing the brush head to be positioned closer to the bristle covering start point.
Solution Approach 2:
The wire is folded from a linear configuration into a three-dimensional U-shaped structure. This dimensional change creates additional gripping surfaces and allows the brush head to be positioned closer to the bristle covering, eliminating the need for extensive distance between components.
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 safe and efficient production of round brushes of various sizes by maintaining bristle coverage up to the brush's end, increasing pull-out resistance, and eliminating the need for manual handling, thus enhancing safety and production efficiency.
Implementation Method 1
a deflecting device with two deflecting rollers spaced apart in the longitudinal direction of a fed wire is provided
Implementation Method 2
a rotary gripper, which is linearly displaceable transversely in relation to the longitudinal direction of the fed wire, for gripping the folded region of the wire
Implementation Method 3
in the region of the unfolded portions of wire there is respectively provided a device for slowing the advancement of the wire
Implementation Method 4
a bristle feeding device, for feeding bristles to the bent-around portions of wire, is provided in the region of the deflecting rollers
Data Source
AI summary
An apparatus for producing round brushes, which have bristles twisted in between two portions of a folded wire. The apparatus has a bristle feeding device and a rotary gripper for twisting two portions of wire with bristles located therebetween, a deflecting device with two deflecting rollers spaced apart in the longitudinal direction of the wire. The rotary gripper is linearly displaceable transversely in relation to the longitudinal direction of the wire, for gripping the folded region of the wire that is formed by force being applied by an application element that is adjustable between the deflecting rollers transversely in relation to the longitudinal direction of the wire. A bristle feeding device, for feeding bristles to the bent-around portions of wire, is provided in the region of the deflecting rollers. In the region of the unfolded portions of wire there is provided a device for slowing the advancement of the wire.