Method and corresponding automatic machine for assembling and shaping circular brushes

Abstract: A system for assembling and shaping semi-finished products (4) consisting of circular brushes comprises a bristle-insertion station (ST2) in which, substantially: a) there is provided a folded circular ring nut (107), which extends axially along its own axis (7x), and has a conical front profiled section (7ap), a central cylindrical portion (7a), a rear circumferential side (7dp) and a central axial hole (7b), fitted onto a ring nut-holder unit (43-39-38) with a conical front head (43); b) a ring (2) is disposed slightly spaced axially in front of the said ring nut (107) and coaxially (2x-7x) relative to the said folded ring nut (107); and c) a plurality of bristles (61) is inserted in a circumferentially distributed manner, by being made to pass between the inner circumference of the said ring (2) and the outer circumference of the said head (43), and thus on the outer circumference of the said ring nut (107), until a specific length (98a) of bristles (61) is obtained, disposed downstream from the said ring (2). A machine for implementation of this system.

Description: Field of the invention -The present invention relates to a method and an automatic machine for assembling and shaping circular brushes (see for example GB-A-637 322). -More particularly, the present invention is included in the specific field of methods and corresponding automatic machines for assembling the components of circular brushes, in order to shape a circular brush semi-finished product, in which each semi-finished product obtained comprises substantially: a circular finished ring nut, which extends axially along its own axis, and has a first circumferential side, a substantially cylindrical central portion, a second circumferential side, and a central axial hole, in which the said two sides form a circumferential channel in the shape of a "U"; a ring, which extends axially along its own axis, and is disposed between the said two circumferential sides of the said finished ring nut, with its own axis disposed coaxially relative to the axis of the finished ring nut; and a plurality of bristles, which are distributed circumferentially and project radially towards the exterior, and are disposed in the shape of a "V", with the vertex inside the said "U"-shaped channel, and with the ring disposed in the vicinity of the convex angle of the "V" itself, which is formed by the said bristles. Technical note -At present, in order to assemble the said components, semi-automatic machines of various types are used, in which, during assembly, external intervention is required by an operator, who must position manually the various components which are designed to shape the circular brush semi-finished product, or by semi-automatic and/or automatic machines, in which multiple operations are required. -This known art has a series of disadvantages. -A first disadvantage is owing to the fact that the presence of an operator gives rise to a corresponding expense which increases the production costs of the corresponding circular brush. -A second disadvantage is owing to the fact that the said multiple operations require a lengthy operating time, with a consequent low production capacity in terms of time, and the adoption of complex, costly machines. -A third disadvantage is owing to the fact that assembly of the bristles is particularly complicated, involves a plurality of operations, and leads to malfunctioning. -A fourth disadvantage is owing to the fact that the length of some bristles in the circular brush semi-finished product obtained is incorrect. Object of the invention -The object of the present invention is to eliminate the above-described disadvantages. -The invention, which is characterised by the claims, solves the problem of creating a method for assembling and shaping circular brush semi-finished products along an assembly line which extends along its own axis, in which each semi-finished product comprises: a circular finished ring nut, which extends axially along its own axis, and has a first circumferential side, a substantially cylindrical central portion, a second circumferential side, and a central axial hole, wherein the said two circumferential sides form a circumferential channel in the shape of a "U"; a ring, which extends axially along its own axis, and is disposed between the said two sides of the said finished ring nut, with its own axis disposed coaxially relative to the axis of the finished ring nut; and a plurality of bristles, which are distributed circumferentially and project radially towards the exterior, and are disposed in the shape of a "V", with the vertex inside the said "U"-shaped channel, and with the ring disposed in the vicinity of the convex angle of the "V" itself, which is formed by the said bristles, wherein the said system is characterised in that it comprises a bristle insertion station in which a)-there is provided a folded circular ring nut, which extends axially along its own axis, and has a conical front profiled section which diverges towards the rear, a central cylindrical portion, an inclined rear circumferential side which diverges towards the rear, and a central axial hole, fitted onto a ring nut-holder unit with a conical front head, the axis of the said coaxial ring nut being disposed coaxially relative to the axis of the said assembly-shaping line; b)-the said ring is disposed slightly spaced axially in front of the said folded ring nut, the axis of the said ring being disposed coaxially relative to the axis of the said assembly-shaping line, and thus coaxially relative to the axis of the said folded circular ring nut; and c)-a plurality of bristles is inserted in a circumferentially distributed manner, by being made to pass between the inner circumference of the said ring and the outer circumference of the said head, and thus on the outer circumference of the said folded circular ring nut, until a specific length of bristles is obtained, disposed downstream from the said ring. -The invention, which is characterised by the claims, also solves the problem of creating a machine for carrying out the method, in which the said machine is characterised in that it comprises an assembly-shaping line which extends axially along its own axis, and includes: a translator-shaft unit, which is mobile axially by command, and can support and translate axially along the said axis of the said assembly-shaping line a ring nut-holder unit, which, going from the front towards the rear, has a conical head, a radial spreader device, and a shaft; a folder-ring nut unit, which is provided with a circular matrix, which extends axially along its own axis, coaxially relative to the axis of the said assembly-shaping line, and can fold an unfinished circular ring nut in order to obtain a conical profiled section which diverges towards the rear in the vicinity of its front head, and an inclined profiled section which also diverges towards the rear of the circumferential side; a ring-holder unit which is designed to hold in position a ring which has its corresponding axis coaxial relative to the axis of the said line; a bristle-cutter unit, which is mobile axially by command, and is designed to cut a plurality of continuous tufts of bristles which are disposed upstream from the said ring, and a bristle-gripper unit, which is mobile axially by command, and is designed to move the said bristles axially relative to the said ring. Description of a preferred embodiment of the invention -Further characteristics and advantages of the present invention will become more apparent from the following detailed description of a preferred practical embodiment, which is provided here purely by way of non-limiting example, with reference to the figures in the attached drawings, in which: Figure 1 is a schematic perspective view of the assembly-shaping machine; Figure 1A is a perspective view of the detail 1A in figure 1; Figure 1C is a general schematic perspective view of the machine during the loading operations; Figure 2 is a general schematic perspective view of the machine at the end of the loading operations; Figure 2A is a lateral schematic view in cross-section, relative to a longitudinal-vertical plane of the machine in figure 2; Figures 2B, 2C, 2D and 2E are respectively enlarged illustrations of the details 2B, 2C, 2D and 2E in figure 2A; Figure 3 is a general schematic perspective view of the machine according to a successive operative step; Figure 3A is a lateral schematic view in cross-section, relative to a longitudinal-vertical plane of the machine in figure 3; Figures 3B and 3C are respectively enlarged illustrations of the details 3B and 3C in figure 3A; Figure 4 is a lateral schematic view in cross-section, relative to a longitudinal-vertical plane of the machine according to a successive operative step; Figures 4A and 4B are respectively enlarged illustrations of the details 4A and 4B in figure 4; Figure 5 is a lateral schematic view in cross-section, relative to a longitudinal-vertical plane of the machine according to a successive operative step; Figures 5A, 5B and 5C are respectively enlarged illustrations of the details 5A, 5B and 5C in figure 5; Figure 6 is a lateral schematic view in cross-section relative to a longitudinal-vertical plane of the machine according to a successive operative step; Figures 6A and 6B are respectively enlarged illustrations of the details 6A and 6B in figure 6; Figure 7 is a lateral schematic view in cross-section relative to a longitudinal-vertical plane of the machine according to a successive operative step; Figures 7A and 7B are respectively enlarged illustrations of the details 7A and 7B in figure 7; Figure 8 is a lateral schematic view in cross-section relative to a longitudinal-vertical plane of the machine according to a successive operative step; Figures 8A and 8B are respectively enlarged illustrations of the details 8A and 8B in figure 8; Figure 9 is a lateral schematic view in cross-section relative to a longitudinal-vertical plane of the machine according to a successive operative step; Figures 9A and 9B are respectively enlarged illustrations of the details 9A and 9B in figure 9; Figure 10 is a lateral schematic view in cross-section relative to a longitudinal-vertical plane of the machine according to a successive operative step; Figures 10A and 10B are respectively enlarged illustrations of the details 10A and 10B in figure 10; Figure 11 is a lateral schematic view in cross-section relative to a longitudinal-vertical plane of the machine according to a successive operative step; Figures 11A and 11B are respectively enlarged illustrations of the details 11A and 11B in figure 11; Figure 12 is a lateral schematic view in cross-section relative to a longitudinal-vertical plane of the machine according to a successive operative step; Figures 12A and 12B are respectively enlarged illustrations of the details 12A and 12B in figure 12; Figure 13 is a schematic perspective view of the shaping machine during unloading of the circular brush semi-finished product obtained; Figures 14 and 14A are respectively a front view and a view in cross-section along the line 14A-14A in figure 14, of a specific device of the shaping machine in a first operative configuration; Figures 15 and 15A are respectively a front view and a view in cross-section along the line 15A-15A in figure 15, of the same aforementioned specific device in a second operative configuration; and Figures 16 and 16A are respectively a lateral schematic view partially in cross-section, and a view in cross-section along the line 16A-16A in figure 16, of the circular brush semi-finished product obtained by means of the method and the machine which are the object of the present invention. Structural description of the machine -With reference to the following description, the operative method and the corresponding automatic assembly-shaping machine, which are both the object of the present invention, are designed to obtain, one after another, circular brush semi-finished products wherein, see figures 16 and 16A, each semi-finished product obtained, which in this case is indicated as 4, substantially comprises: a circular finished ring nut 1, which extends axially along its own axis 1x, and has a first circumferential side 1c, a substantially cylindrical central portion 1a, a second circumferential side 1d, and a central axial hole 1b, in which the said two circumferential sides 1c and 1d form a circumferential channel in the shape of a "U"; a ring 2, which extends axially along its own axis 2x, and is disposed between the said two circumferential sides 1c and 1d of the said finished ring nut 1, with its own axis 2x disposed coaxially relative to the axis 1x of the finished ring nut 1; and a plurality of bristles 3, which are distributed circumferentially and project radially towards the exterior, and are disposed in the shape of a "V", with the vertex inside the said "U"-shaped channel, and with the ring 2 disposed in the vicinity of the convex angle of the "V" itself, which is formed by the said bristles 3. -With reference to figures 1, 1C, 2 and 2A, the assembly-shaping machine extends longitudinally, and has centrally an assembly-shaping operative line indicated as 5 as a whole, which is described in greater detail hereinafter, and is designed to assemble and shape the said circular brushes 4, and is such that the said assembly-shaping line 5 extends along its own longitudinal axis, which is indicated as 5x in figure 2A and in the subsequent lateral views. -On a first side of the said assembly-shaping line 5, there are disposed first supply means, indicated as 6 as a whole, which are designed to supply one after another unfinished circular ring nuts indicated as 7, which, see also figure 2C, extend axially along their own axis 7x, and, substantially, have a cylindrical front portion 7a, a rear circumferential side 7d which is oriented at 90° relative to the said axis 7x, and a central axial hole 7b. -Again on the said first side, but in a position which is further forwards, there are disposed second supply means with several elements, indicated as 8a-8b-8c, which are designed to supply one after another the rings 2, which, see figure 2E, extend axially along their own axis 2x. -The first ring nut supply means 6, see figure 1, substantially comprise a gripper 9 with tines 9a and 9b, which is supported by an articulated, rotary mechanical cuff 10, such that the said gripper 9 collects the unfinished ring nuts 7 individually in succession, in the vicinity of the downstream end of a hopper 11, and then translates them positively towards, and into, the assembly-shaping line 5, see also figures 1C, 2 and 2A, and then keeps them in position inside the said assembly-shaping line 5, by disposing the axis 7x of the unfinished circular ring nut 7 coaxially relative to the axis 5x of the assembly-shaping line 5, see figure 2C. -The second supply means 8a-8b-8c substantially comprise: a store 8a, which is designed to contain stacked vertically a plurality of rings 2, and to collect and present individual rings 2 in succession, by extracting the latter individually from the base of the stack; a translator 8b, which is designed to grasp the rings 2 presented by the store 8a, and then to translate them; and an articulated positioner 8c, which is designed to grasp the rings 2 presented by the said translator 8b and position them inside a recess 12a in an upper shell 14a of a ring support 22. -On the other side of the assembly-shaping line 5, i.e. on the second side, there are disposed collection-removal means 13, which, see also figure 13, are designed to collect the brush semi-finished products 4 from the assembly-shaping line 5, in order to remove them, such as to permit execution of a new operative cycle. -With reference to figure 1, going from the right towards the left, the assembly-shaping line 5 comprises: a translator-shaft unit 20, a folder-ring nut unit 21, a ring-holder unit 22, a bristle-cutter unit 23, and a bristle-gripper unit 24. -The translator-shaft unit 20, see in particular figures 1 and 2A, is supported by a first slide 25, which has a lower portion which is connected prismatically to longitudinal guides 26, which are secured to a table 27, and a central portion, which is connected helically to a screw 28, which is actuated by a servomotor 29, for example by means of a helical coupling of the ball-circulation screw type, in order to be able to move the slide 25 axially, by command, and at the required speed of motion and axial thrust, and thus the said translator-shaft unit 20, in both axially opposite directions, as indicated by the arrow F1. -The said translator-shaft unit 20, see in particular figure 2A, substantially comprises a cylindrical support 30, which is secured to the first slide 25, inside which there is disposed a tube 31, which is rotably connected such as to rotate with respect to said cylindrical support 30, and the said tube 31 has a length such as to have two opposite ends 32 and 33 which project axially relative to the said cylindrical support 30. -The first end 32 of the said tube 31 supports integrally the lower end of an arm 34, which has an upper forked portion with tines 35a and 35b, wherein the latter are engaged by a cam 36, which is rotated by means of a servomotor 37 secured to the slide 25, such that when the servomotor 37 is actuated, the said tube 31 is oscillated angularly. -The second end 33 of the said tube 31 has secured to it a hollow shaft-mould 38, inside which there is partially disposed a radially expandable spreader device 39, wherein, see in particular figures 1A, 2A and 2B, the corresponding clamps 39a-39b-39c-39d-etc, which are disposed circumferentially equidistantly, are supported by corresponding levers 58a-58b-etc., which are pivoted at 59a-59b-etc., inside the said hollow shaft-mould 38, and wherein the said clamps 39a-39b-39c-39d-etc., in order to be able to be expanded radially by command, see also figure 11A, are engaged by a cone 40, which is secured to the end of a shaft 41 which has a square transverse cross-section, such that the latter is connected prismatically in a sliding manner, axially inside the said tube 31. By means of a rotary coupling 41a, the other free end of the said shaft 41 is moved in both axial directions by means of a hydraulic jack 42, which is also secured to the slide 25. -At the free end of the cone 40, there is disposed a conical head 43, which preferably has a curved profiled section, which, see in particular figure 1A, can optionally be provided with a plurality of etched longitudinal grooves 44a-44b-44c etc., which are circumferentially equidistant. -With particular reference to the head 43, the clamps 39a-39b-39c-etc., and to the shaft-mould 38, it must be emphasised, for the reasons which will become apparent hereinafter, that these items form a ring nut-holder unit 43-39-38, which is designed to engage the hole 7b in the unfinished ring nuts 7, wherein the said ring nut-holder unit 43-39-38 has an outer profiled section which, going from the left towards the right, i.e. from the front towards the rear, has: a first curved conical profiled section 56a, provided with longitudinal notches 44, with a maximum diameter which is smaller than the diameter of the hole 7b in the ring nut 7, a second cylindrical profiled section 56b, which has a diameter smaller than the maximum diameter of the profiled section 56a, defining a circumferential groove 56b in the said ring nut-holder unit 43-39-38, a third profiled section 56c, which has a diameter which is substantially the same as that of the hole 7b in the ring nuts 7, and a fourth, diverging conical profiled section 56d. -The ring nut-folder unit 21, see also figures 14, 14A, 15 and 15A, substantially comprises a vertical-transverse thrust plate 45, which is provided with a central hole 45a, and is rendered integral with the base 27 by means of a horizontal plate 46, and by means of two lateral walls 46b which act as a connection plate, only one of which can be seen in the figures. -The vertical-transverse plate 45, at the right with reference to the illustrations 14A and 15A, has two half-shells 47a and 47b, which are disposed such that they abut this vertical-transverse plate 45, and are supported by a corresponding end portion of two corresponding levers 48a and 48b, which each have their opposite ends pivoted at 49 on a further lateral support 50, which supports in a pivoting manner two fluid-dynamics cylinders 51a and 51b, which, by means of corresponding articulations 52a-53a and 52b-53b, by command, bring close to one another the said two half-shells 47a and 47b, see figures 14 and 14A, in order to form a matrix 47a-47b, or, again by command, place the said two half-shells 47a and 47b in an open position, see figures 15 and 15A, in order to permit free axial advance, through the said open matrix 47a-47b, and through the hole 45a, of the ring nut 7, folded as described in greater detail hereinafter. -With particular reference to the matrix 47a-47b, it must be emphasised, for the reasons which will become apparent hereinafter, that the latter has an outer profiled section, which, going from left to right, i.e. from the front to the rear, see in particular figure 2D, comprises a cylindrical profiled section 60a, a conical profiled section 60b which diverges towards the rear, and has a maximum diameter which is substantially the same as the outer diameter of the cylindrical portion 7a of the ring nut 7, a cylindrical profiled section 60c which has a diameter which is slightly larger than the outer diameter of the cylindrical portion 7a of the unfinished ring nut 7, and a conical profiled section 60d which diverges towards the rear. -The ring-holder unit 22, see figures 1, 2E and 2, substantially comprises a lower shell 14b, which is secured to the base 27, and is designed to have a lower recess 12b for the rings 2, and also the upper half-shell 14a, which is designed to have an upper recess 12a for the ring 2 as previously described, see also figures 3 and 3C, wherein the said upper half-shell 14a is pivoted on the lower shell 14b at 54, such that it can be pivoted into the opening or closing position, by command, by means of a jack 57a-57b, wherein the latter has a cylinder 57a which is secured to the base 27, and a rod 57b which is pivoted at 55 on the said upper half-shell 14a. -By means of this structure, by command, it is possible to put the ring-holder unit 22 into the opening position, see figures 1 and 1C, with the two half-shells 14a and 14b open, in order to be able to position a ring 2, by means of the ring-supply means 8a-8b-8c, in the recess 12a, or, see figure 13, in order to be able to collect a circular brush semi-finished product 4 which has the corresponding ring 2 inserted in the recess 12b, as described in greater detail hereinafter, by means of the collection-removal means 13, and also, see figures 3 and 3A, to be able to place the ring-holder unit 22 in the closed position, with the two half-shells 14a and 14b close to one another, such as to hold the ring 2 firmly in the correct position inside the recesses 12a and 12b. -The bristle-cutter unit 23, see also figures 10 and 10A, is designed to cut a plurality of tufts 60a-60b-etc., and eight tufts in the case illustrated, which are disposed circumferentially equidistantly around an original circumference, such that each tuft, see 60a, consists of a mass of bristles 61a-61b-61c-etc., which can be made of plastics and/or metal material, and/or can be of another type. -The tufts 60a-60b-etc. are contained in a sliding manner inside eight telescopic tubes 62a-62b-etc., see figure 1, which are also disposed circumferentially equidistantly around a single original circumference, wherein the said telescopic tubes 62a-62b-etc., see figure 10A, have first segments 63a-63b-etc., which have their free end secured at the corresponding eight axial holes 64a-64b-etc., which are provided in a rotary blade 65 of the bristle-cutter unit 23, and, in an opposite direction, second segments 66a-66b-etc., which have their free end secured at eight corresponding axial holes 67a-67b-etc., provided in a first jaw 68 in the bristle-gripper unit 24, which is described in greater detail hereinafter. -The said bristle-cutter unit 23 substantially and schematically comprises the said rotary blade 65, the holes 64a-64b-etc. which have sharp inner angles in the vicinity of their right end, wherein the said rotary blade 65 is supported such that it can rotate, by means of a pin 99, which is presented by a fixed blade 70 which is disposed adjacent, and is also provided with a corresponding plurality of axial holes 71a-71b-etc., which have sharp inner angles in the vicinity of their left end, and wherein the said fixed blade 70 is secured onto a second slide-74, which can slide axially, and is connected prismatically onto longitudinal guides 75 which are secured to the base 27. -In addition, see also figure 1, the rotary blade 65 has a flange 73, which extends radially on one side, and is engaged by a jack 76a-76b, which has a cylinder 76a pivoted at 77 on the said slide 74, and the free end of a corresponding rod 76b pivoted at 78 on the radial end of the said flange 73, such that when the jack 76a-76b is actuated, i.e. by command, the rotary blade 65 rotates, whereas the blade 70 remains fixed, such that all eight tufts 60a-60b-etc. of bristles which are engaged in the corresponding eight holes 64a-71a, 64b-71b etc, will be cut off, as illustrated at Ta and Tb in figure 10A. -The bristle-gripper unit 24, substantially and schematically, see also figure 10A, comprises the first jaw 68 which rotates freely, and is also provided with a corresponding number of. eight cylindrical holes 67a-67b-etc., and is rotably connected such as to rotate with respect to a vertical support 79, which is secured to a third slide 80, which also slides axially, and is connected prismatically to the guides 75, which are secured to the base 27. -Adjacent to the said first jaw 68, there is disposed a second jaw 81, which is also provided with a corresponding plurality of eight cylindrical holes 82a-82b-etc., and is supported such as to rotate by the said first jaw 68, by means of a pin 83, wherein the said second jaw 81 is integral with a toothed segment 84, see also figure 1, the toothing of. which is engaged with a pinion 85, wherein the latter is supported in a projecting manner by a shaft 88, which is supported such as to rotate by a flange 89, which is integral with the first jaw 68, and wherein the said shaft can be rotated by means of a servomotor 90, preferably of the hydraulic type, which is also secured to the said flange 89. -By means of this structuring, by actuating the servomotor 90, see figure 10B, it is possible to change the angular position between the said two jaws 81 and 68, as well as to generate and maintain torque between the said two jaws 81 and 68, such as to offset the axial alignment between the holes 82 and 67, and thus to constrict the tufts of bristles 60, in order to inhibit axial sliding of the corresponding bristles 61 relative to the bristle-gripper unit 24, or, on the other hand, see figure 9B, to align the holes 82 and 67 axially, in order to allow the tufts 60, and thus the corresponding bristles 61, to slide axially relative to the said bristle-gripper unit 24. -Again with reference to the said bristle-gripper unit 24, see figure 1, for the reasons which will become apparent hereinafter, it should be noted that the jaw 68, which rotates freely, is interconnected by means of a telescopic bar 72 to the rotary blade 65, such as to rotate integrally with the latter. The second slide 74, which is designed to support the bristle-cutter unit 23, and the third slide 80, which is designed to support the bristle-gripper unit 24, are interconnected axially by means of a least one pneumatic jack 91a-91b (it is also possible to provide a second jack on the opposite side), which acts as a pneumatic spring, wherein the said jack 91a-91b has a cylinder 91a which is rendered integral with the third slide 80, and a rod 91b, which is rendered integral with the second slide 74. -In addition, the third slide 80, see in particular figure 10, has a portion which is connected helically to a screw 94 which is actuated by a servomotor 95, for example by means of a helical coupling of the ball circulation screw type, in order to be able to move the said bristle-gripper unit 24 axially, by command, at the required speed of motion and axial thrust, in the directions indicated by the arrow F2, and consequently, by means of the pneumatic jack 91a-91b, the said bristle-cutter unit 23, as described in greater detail hereinafter. -The third slide 80 also supports vertical supports 95a and 95b, which are designed to support tubes 97a-97b-97c-etc., which are also disposed circumferentially spaced, and are of a number which is equivalent to the number of holes in the bristle-gripper unit 23 and in the bristle-cutter unit 22, wherein the said tubes 97a-97b-97c-etc. encase in a sliding manner the multiple tufts 60a-60b-etc. -Upstream or to the left of the said tubes 97a-97b-97c-etc., there are disposed devices for shaping and/or supply of the tufts 60a-60b-etc., which are not described or illustrated here, since they are not included in the inventive concepts of the present invention. -The said machine is also provided with electrical and/or electronic and/or mechanical and/or computerised synchronisation means, to manage the control and actuation of the various sensor and actuator means. Description of operation -Operation of the assembly-shaping machine which is previously described from a structural point of view, and in particular the operative cycle in order to obtain circular brush semi-finished products 4 in succession, one after the other, consists initially, see figures 1, 1C, 2, 2A, 2C and 2E, of loading the assembly-shaping line 5. -More particularly, this loading, see figure 1, consists of collection of an unfinished ring nut 7 from the downstream end of the hopper 11, by means of the gripper 9 with tines 9a and 9b, and, see figures 2, 2A, 2C, positioning of the unfinished ring nut 7 itself within the said assembly-shaping line 5, by placing the axis 7x of the said unfinished ring nut 7 coaxially relative to the axis 5x of the assembly-shaping line 5. -In addition, this loading, again see figure 1, consists of presentation by the store 8a of a ring 2, collection of the latter by the means 8b, and translation towards the means 8c, grasping of the ring 2 itself by means of the said means 8c, and positioning of the ring (see figure 1C) inside the upper circular recess 12a in the upper half shell 14a of the ring-holder means 22, where it is gripped; the positioner 8c is then moved away (see figure 2), and the upper half-shell 12a is then closed by means of actuation of the jack 57a-57b, and the ring 2 is also placed inside the recess 12b in the lower half-shell 14, such as to position the axis 2x of the said ring 2 coaxially relative to the axis 5x of the assembly-shaping line 5. -Thus, when the loading has taken place, the configuration illustrated in figure 2A, and in the corresponding details 2B, 2C, 2D and 2E is obtained. -With reference to figures 3 and 3A, by actuating the servomotor 29, the first slide 25 has been advanced towards the left, with consequent advance of the ring nut-holder unit 43-39-38, which, since it is also coaxial relative to the axis 5x of the line 5, optionally with the thrust provided by the conical head 43, is inserted correctly inside the hole 7b in the unfinished ring nut 7, which is held in position by the tines 9a and 9b of the gripper 9, until the configuration illustrated in figure 3b is obtained, in which the gripper 9 has been returned to its position adjacent to the slide 11, for execution of a successive supply operation, see figure 3. With reference to figures 4 and 4A, the unfinished ring nut 7 has been advanced further towards the left by the ring nut-holder unit 43-39-38, and into a folding station ST1, in which, more particularly, the said unfinished ring nut 7 has been conveyed against the matrix 47a-47b of the ring nut-folder unit 21, which has the two half-shells 47a and 47b in the closing position, and, owing to the profiled sections 60a-60b-60c-60d which are present in the said matrix 47a-47b, and to the profiled sections 56a-56b-56c-56d which are present in the said ring nut-holder unit 43-39-38 which acts as a mould, the unfinished ring nut 7 itself undergoes initial folding, which, in the vicinity of its front cylindrical portion 7a, is designed to form a conical profiled section 7ap which diverges towards the rear, the front head of the said conical profiled section 7ap being disposed circumferentially inside the profiled groove 56b, and in addition it undergoes second folding, which is designed to fold the perpendicular side 7d towards the rear, thus obtaining an inclined side 7dp, which provides a folded circular ring nut indicated hereinafter as 107. -With reference to figures 5 and 5A, by means of actuation of the two fluid-dynamics cylinders 51a and 51b, see also figures 14 and 15, the two half shells 47a and 47b have been disposed in the opening position, and, by means of actuation of the servomotor 29, the ring nut-holder unit 43-39-38, together with the corresponding folded circular ring nut 107, has been advanced further towards the left, and, after passing through the hole 45a in the vertical-transverse thrust plate 45, has been stopped in a bristle-insertion station, indicated as ST2, in which the head 43 of the ring-nut unit 43-39-38 is partially inserted in the ring 2, which is held in position by the ring-holder unit 22. -Again with reference to figures 5 and 5B, in the operative cycle previously described, as will become more apparent hereinafter, the bristle-cutter unit 23 has cut the continuous tufts 60a-60b-etc., in the vicinity of the points Ta-Tb-etc., and, also, see figure 5C, the two jaws 68 and 81 of the gripper unit 24 have the corresponding holes 82a-67a, 82b-67b etc. non-aligned axially with one another, such as to clamp-constrain the tufts 60a-60b-etc., and thus to inhibit axial sliding of the corresponding bristles 61. -With reference to figures 6, 6A and 6B, whilst maintaining the bristle-gripper unit 24 in the position for clamping of the tufts 60a-60b-etc., and actuating the servomotor 95, the slide 80 has been advanced towards the ring-holder unit 22, thus also advancing the slide 74 by means of the pneumatic jack 91a-91b, and during this advance, in sequence, firstly the blade 70 meets the ring-support unit 22, and then, whilst the slide 80 is continuing to advance, and to compress the pneumatic jack 91a-91b as a result of the corresponding axial movement of approach which is generated between the bristle-gripper unit 24 and the bristle-cutter unit 23, the free ends of the bristles 61 of the tufts 60a-60b-60c-etc. are inserted between the inner diameter of the ring 2 and the outer diameter of the head 43 with a curved profiled section. -More particularly, see figure 6A, during this insertion step, the front ends of the bristles 61 of the tufts 60a-60b-etc. firstly meet a conical surface 70c which is presented by the said bristle-cutter unit 23, and arranges the bristles in the shape of a fan, and subsequently, the bristles meet the head 43, and are inserted partially inside the longitudinal notches 44 (see figure 1A), and then pass through the gap formed between the inner circumference of the ring 2 and the head 43 itself, and then move towards the folded circular ring nut 107. -Again at least during the said step of insertion of the bristles 61 of the tufts 60a-60b-etc., the head 43 and the hollow mould-shaft 38, and thus also the folded circular ring nut 107 which is fitted onto the said shaft 38, are made to oscillate angularly relative to the axis 5x of the assembly-shaping line 5, by means of actuation of the servomotor 37, which makes the tube 31 oscillate angularly. -With particular reference to figure 6A, it must also be pointed out that the front ends of any bristles 61 which project axially against the front head of the ring nut 7 will not be subject to collisions against the said head, since, see for example the bristle 61y in figure 6A, the front end of the said bristle 61y meets the conical profiled section 7ap of the folded circular ring nut 107 with an angle of incidence which is not perpendicular, and therefore it will immediately be deflected radially towards the exterior, also as a result of the angular oscillations which the said head 43 and the said folded circular ring nut 107 undergo. -Again in this context, it must be pointed out that the front ends of any other bristles 61 which project axially against the side 7dp of the folded ring nut 107 will not be subject to collisions against this side 7bp, since, see for example the bristle 61z in figure 6A, the front end of the said bristle 61z meets the conical profiled section 7dp of the semi-finished ring nut 107 with an angle of incidence which is not perpendicular, and therefore it will immediately be deflected radially towards the exterior, also as a result of the angular oscillations which the said head 43 and the said folded circular ring nut 107 undergo. -With reference to figures 7, 7A and 7B, by means of actuation of the servomotor 95, the slide 80 has been further advanced towards the right until it stops at a pre-determined point, in order to provide a specific length 98a of bristles 61 downstream from the ring 2. -With reference to figures 8, 8A and 8B, after having inserted the required length 98a of bristles, whilst keeping the bristle-gripper unit 23 in the clamping position, by means of actuation of the servomotor 29, the slide 25 and the corresponding translator-shaft unit 20 which supports the ring nut-holder unit 43-39-38, have been advanced towards the said ring 2, until the bristles 61a-61b-61c-etc are gripped between the inner diameter of the said ring 2 and the ring nut 107, with an intensity which inhibits axial sliding of the bristles. -With reference to the aforementioned phase which is designed to obtained a specific length 98a of bristles 61 downstream from the said ring 2, in the case of particular types of bristles, it may happen that some bristles, see for example the bristle 61k illustrated in figure 6A, during insertion, which is obtained by applying axial thrust at a point upstream from the said bristle 61k, i.e. between the two jaws 81-68, undergo excessive abnormal flexure Fk, such that the portion of bristle 61k which is disposed downstream from the ring 2 is shorter than the required length 98a, and than the length of the other bristles 61. -In order to eliminate this disadvantage, if necessary, the bristle-gripper unit 24 is advanced towards the said ring 2, until there is obtained downstream from the said ring 2 a portion of bristles which have a length longer than the required length 98a, and subsequently, the bristle-gripper unit 24 is withdrawn in relation to the said ring 2, i.e. axial traction is applied on the bristles 61, until the required length 98a of bristles 61 is obtained downstream from the said ring 2. -By this means, any incorrect flexure Fk of the bristle 61k which took place during the first, axial thrust phase is eliminated during the second, axial traction phase, wherein the said latter phase is designed to determine the required length 98a of bristles disposed downstream from the said ring 2. The said second phase, again if necessary, can also be carried out after the ring nut 107 and the ring 2 have been brought close to one another. -With reference to figures 9, 9A and 9B, after the bristles have been gripped between the ring 2 and the folded ring nut 107, by command, by actuating the servomotor 90, the bristle-gripper unit 23 has been placed in the opening position, i.e. with the holes 82a-67a, 82b-67b etc aligned axially, in order to obtain release of the various tufts 60a-60b-etc., which can now slide freely through the said bristle-gripper unit 24, and therefore move the slide 80 towards the left by actuating the servomotor 95, obtaining initially displacement towards the left of the bristle-gripper unit 24, with extension of the jack 91a-91b, and, when the latter is just in the vicinity of its end of travel, withdrawal of the slide 74, and therefore of the corresponding bristle-cutter unit 23, whereas the tufts 60a-60b-etc. of bristles 61 have continued to be at a standstill and stationary, since they are gripped between the ring 2 and the folded ring nut 107. -With reference to figures 10, 10A and 10B, when the slide 80 has reached a pre-determined axial position in which, preferably, the length of the bristles 61 which is upstream from the ring 2, and is indicated as 98b, is the same as the preceding length 98a of the same bristles 61 disposed downstream from the ring 2, i.e. in which, substantially, a required distance has been reached between the cutting point Ta-Tb-etc. of the bristle-cutter unit 23 and the ring 2, firstly the servomotor 95 has been stopped, and the bristle-gripper unit 23 has been placed in the clamping position, and then, by means of actuation of the jack 76a-76b, the rotary blade 65 has been rotated, with consequent cutting of the bristles 61a-61b-61c-etc. of each tuft 60a-60b-etc., at the points Ta-Tb-etc., i.e. at the required point. -In this context, in the particular practical embodiment described, in which eight tufts/holes are provided, the said tufts 60a-60b-etc. are cut by means of angular rotation by 45° of the rotary blade 65, which is equivalent to the angular distance between two adjacent circumferential holes/tufts, such that when the cutting is completed, the holes 64a-64b-etc., in the rotary blade 65 will once more be aligned axially with the holes 71a-71b-etc. in the fixed blade 70, but offset by one angular step relative to the original position. -In addition, for the reasons which will become apparent hereinafter, owing to the telescopic bar 72 which interconnects the rotary blade 65 and the jaw 68, the said rotation by 45° of the rotary blade 65 gives rise to rotation by 45° of the bristle-gripper unit 24, and more particularly of the assembly formed by the jaw 68, the flange 89, the motor 90, the pinion 85, the segment 84, and the other jaw 81. -With reference to figures 11, 11A and 11B, by means of actuation of the jack 42, the shaft 41 and the corresponding associated cone 40 have been displaced towards the left, and the said cone 40, by acting on the jaws 39a-39b-39c-etc., has expanded the latter radially towards the exterior, with consequent radial folding towards the exterior of the front edge 7ap-7a of the ring nut 107, and corresponding shaping of the side 1c, thus providing the semi-finished product indicated as 4 in figures 16 and 16A. -With reference to figures 12, 12A and 12B, after the aforementioned shaping has taken place, the shaft 41 has been returned to its original position, and, by actuating the servomotor 29, the slide 25, and thus the corresponding translator-shaft unit 20, have been displaced towards the right, whereas the semi-finished product 4 has remained fixed, since the ring 2 is clamped in the ring-holder unit 22. -Finally, with reference to figure 13, after the upper half-shell 14a of the ring-holder means 22 has been opened, the collection means 13 have collected the circular brush semi-finished product 4, and have then removed it in order to be able to carry out a new operative cycle. -The new operative cycle will substantially be similar to the previous one, and the only difference consists in the fact that, in order to cut the bristles, i.e. in order to carry out the operation illustrated in figure 10, the rotary blade 65 is rotated in the opposite direction, again by 45°, thus, again owing to the telescopic interconnection bar 72, obtaining rotation by 45° of the bristle-gripper unit 24, in a direction opposite to that in the previous case, thus obtaining once again the configuration in figure 9. -The preceding description of the method and of the corresponding assembly-shaping machine is provided purely by way of non-limiting example, and it is thus apparent that all modifications and/or variants suggested by practice and by utilisation and use can be made to this method and machine, within the context of the scope of the following claims.

Claims: Method for assembling and shaping circular brush semi-finished products (4) along an assembly line (5) which extends along its own axis (5x), in which each semi-finished product (4) comprises: a circular finished ring nut (1), which extends axially along its own axis (1x), and has a first circumferential side (1c), a substantially cylindrical central portion (1a), a second circumferential side (1d), and a central axial hole (1b), wherein the said two circumferential sides (1c, 1d) form a circumferential channel in the shape of a "U"; a ring (2), which extends axially along its own axis (2x), and is disposed between the said two sides (1c, 1d) of the said finished ring nut (1), with its own axis (2x) disposed coaxially relative to the axis (1x) of the finished ring nut (1); and a plurality of bristles (3), which are distributed circumferentially and project radially towards the exterior, and are disposed in the shape of a "V", with the vertex inside the said "U"-shaped channel, and with the ring (2) disposed in the vicinity of the convex angle of the "V" itself, which is formed by the said bristles (3), characterised in that it comprises a bristle insertion station (ST2) in which: a)-there is provided a folded circular ring nut (107), which extends axially along its own axis (7x), and has a conical front profiled section (7ap) which diverges towards the rear, a central cylindrical portion (7a), an inclined rear circumferential side (7dp-1d) which diverges towards the rear, and a central axial hole (7b), fitted onto a ring nut-holder unit (43-39-38) with a conical front head (43), the axis (7x) of the said ring nut (107) being disposed coaxially relative to the axis (5x) of the said assembly-shaping line (5); b)-the said ring (2) is disposed slightly spaced axially in front of the said folded ring nut (107), and the axis (2x) of the said ring (2) is disposed coaxially relative to the axis (5x) of the said assembly-shaping line (5), and thus coaxially relative to the axis (7x) of the said folded circular ring nut (107); and c)-a plurality of bristles (61) is inserted in a circumferentially distributed manner, by being made to pass between the inner circumference of the said ring (2) and the outer circumference of the said head (43), and thus on the outer circumference of the said folded circular ring nut (107), until a specific length (98a) of bristles (61) is obtained, disposed downstream from the said ring (2). Method according to claim 1, characterised in that after phase c), the following operations take place: d)-the folded circular ring nut (107) is pressed axially against the ring (2), in order to inhibit axial sliding of the bristles (61a-61b-61c-etc.) between the said two elements (107, 2); e)-the said plurality of continuous bristles (61a-61b-61c-etc.) is cut at a point upstream from the said ring (2), in order to obtain a specific length (98b) of bristles (61) disposed upstream from the said ring (2); and f)-the front portion (7ap-7a) of the folded ring nut (107) is expanded radially in order to form a further side (1c). Method according to claim 1, characterised in that the said conical head (43) has a plurality of longitudinal notches (44) disposed circumferentially. Method according to claim 1, characterised in that at least during the phase c), the said head (43) oscillates angularly relative to its own axis (5x). Method according to claim 1, characterised in that at least during the phase c), the said ring nut (107) oscillates angularly relative to its own axis (7x). Method according to claim 1, characterised in that, in the phase c): c1)-the bristles (61) are thrust axially towards the said ring (2) and towards the said folded circular ring nut (107), until a length of bristles which is longer than the required length (98a) is obtained downstream from the said ring (2); and c2)-axial traction is exerted on the bristles (61) themselves, until the required length (98a) of bristles (61) is obtained downstream from the said ring (2). Method according to claim 1, characterised in that before the said bristle-insertion station (ST2), there is provided a folding station (ST1) in which: there is placed an unfinished circular ring nut (7), which extends axially along its own axis (7x), and has a cylindrical front portion (7a), a rear circumferential side (7d) and a central axial hole (7b) fitted onto a ring nut-holder unit (43-39-38) which has a shaft-mould (38), such as to dispose the axis (7x) of the said unfinished ring nut (7) coaxially relative to the axis (5x) of the said assembly-shaping line (5); there is provided a circular matrix (47a-47b), which extends along its own axis (47x), in front of the said unfinished ring nut (7), and the axis (47x) of the said circular matrix (47a-47b) is disposed coaxially relative to the axis (5x) of the said assembly-shaping line (5), and thus coaxially relative to the axis (7x) of the said unfinished ring nut (7); the said unfinished ring nut (7) is deformed by being pressed between the said shaft-mould (38) and the said matrix (47a-47b), in order to obtain a folded circular ring nut (107) which has a front conical profiled section (7ap) which diverges towards the rear, and an inclined rear circumferential side (7dp) which diverges towards the rear. Method according to claim 7, characterised in that the said matrix (47a-47b) comprises two half-shells (47a, 47b), which are mobile in a vertical-transverse plane, such that they can be placed in a first position, of closure, in which the said two half-shells (47a, 47b) form a circular matrix (47a-47b) which has its axis (47x) disposed coaxially relative to the axis (5x) of the line (5), and in a second position, of opening, in which the said two half-shells (47a, 47b) are open in order to permit free passage of the semi-finished ring nut (7) through the latter. Method according to claim 8, characterised in that on the side opposite the thrust side of the said matrix (47a-47b), there is disposed a vertical-transverse thrust plate (45), which is provided with a central hole (45a), the axis (45x) of which is coaxial relative to the axis (5x) of the said line (5), and the diameter of which is larger than the maximum diameter of the semi-finished ring nut (7). Method according to any one of the preceding claims, characterised in that going from the front towards the rear, the said ring nut-holder unit (43-39-38) has a conical head (43), which is designed to guide the bristles (61) during insertion of the latter, a radial spreader device (39), which is designed to expand radially the front portion of the folded ring nut (107), and a shaft-mould (38), which is designed to fold the unfinished ring nut (7). Method according to any one of the preceding claims, characterised in that going from the front towards the rear, the said ring nut-holder unit (43-39-38) has a conical profiled section (56a), which has a maximum diameter smaller than the diameter of the hole (7b) in the ring nut (7), a profiled section (56b), which has a diameter smaller than the maximum diameter of the preceding conical profiled section (56a), defining a circumferential groove (56b) in the said ring nut-holder unit (43-39-38), a profiled section (56c), which has a diameter which is substantially the same as that of the hole (7b) in the ring nuts (7), and a conical profiled section (56d) which diverges towards the rear. Method according to claim 11, characterised in that the front head of the front conical profiled section (7ap), which diverges towards the rear of the folded circular ring nut (107), is disposed circumferentially inside the circumferential groove (56b) provided by the said ring nut-holder unit (43-39-38). Machine for carrying out the method according to the preceding claims, characterised in that it comprises an assembly-shaping line (5) which extends axially along its own axis (5x), and includes: a translator-shaft unit (20), which is mobile axially by command, and can support and translate axially along the said axis (5x) of the said assembly-shaping line (5) a ring nut-holder unit (43-39-38), which, going from the front towards the rear, has a conical head (43), a radial spreader device (39) and a shaft (38); a ring nut-folder unit (21), which is provided with a circular matrix (47a-47b), which extends axially along its own axis (47x), coaxially relative to the axis (5x) of the said assembly-shaping line (5), and can fold an unfinished circular ring nut (7), in order to obtain a conical profiled section (7ap) which diverges towards the rear, in the vicinity of its front head, and an inclined profiled section (7dp), which also diverges towards the rear of the circumferential side (7d); a ring-holder unit (22), which is designed to hold in position a ring (2), with the corresponding axis (2x) coaxially relative to the axis (5x) of the said line (5); a bristle-cutter unit (23), which is mobile axially by command, and is designed to cut a plurality of tufts (60) of continuous bristles (61), which are disposed upstream from the said ring (2); and a bristle-gripper unit (24), which is mobile axially by command, and is designed to move the said bristles (61) axially relative to the said ring (2). Machine according to claim 13, characterised in that the said translator-shaft unit (20) is supported by its own slide (25), which has a lower portion which is connected prismatically to longitudinal guides (26), which are secured to a table (27) of the machine, and a central portion, which is connected helically to a screw (28), which is actuated by a servomotor (29). Machine according to claim 13, characterised in that the said bristle-gripper unit (24) is supported by its own slide (80), which has a lower portion which is connected prismatically to longitudinal guides (75), which are secured to a table (27) of the machine, and a central portion, which is connected helically to a screw (94), which is actuated by a servomotor (95). Machine according to claim 15, characterised in that the said bristle-cutter unit (23) is supported by its own slide (74), which has a lower portion which is connected prismatically to longitudinal guides (75), which are secured to a table (27) of the machine, and in that the said slide (74) is interconnected axially to the said slide (80), which is designed to support the bristle-gripper unit (24) by means of a jack (91a-91b). Machine according to any one of claims 13 to 15, characterised in that the said bristle-gripper unit (24) comprises: a vertical support (79); a first jaw (68), which is provided with a plurality of axial holes (67a-67b-etc.), disposed circumferentially, which is rotably connected such as to rotate with respect to said vertical support (79); a second jaw (81), which is disposed adjacent to the said first jaw (68), and is also provided with a corresponding plurality of axial holes (82a-82b-etc.) disposed circumferentially, and is supported such as to rotate by the said first jaw (68) by means of a rotation pin (83); a toothed segment (84), which is integral with the said second jaw (81), and is designed to move the said first jaw (68) angularly relative to the said rotation pin (83); and a pinion (85), which is engaged on the said circular segment (84), supported by a flange (89) which is integral with the first jaw (68), and is actuated by means of a servomotor (90) which is also secured to the said flange (89). Machine according to claim 17, characterised in that the said bristle-gripper unit (24) has the first jaw (68) interconnected by means of a telescopic bar (72) to a rotary blade (65) of the bristle-cutter unit (24), such that the rotations of the said rotary blade (65) give rise to rotation of the assembly formed by the first jaw (68), the flange (89), the motor (90), the pinion (85), the segment (84) and the second jaw (81).

Inventors: NADALINI RAFFAELE, ROMAGNOLI MARINO, NADALINI, RAFFAELE, ROMAGNOLI, MARINO
Applicants: UNIMAC SRL, UNIMAC S.R.L.
Application year: 2000
Main classification: A46D3
IPC codes: A46B13, A46D3