Patent Description:
The related hair planting apparatus holds a mesh-like base material for hair planting, and uses a plurality of hook needles to form a knot of hair for planting into individual mesh holes of the base material to perform hair planting (for example, see <CIT>).

In the above-mentioned related hair planting apparatus, it is possible to move a base material in one section within the range of the opening of a pressing frame by means of the X-Y moving mechanism, but when finishing the hair planting within the section and moving to the next section to continue the hair planting, an operation of manually reattaching the pressing frame of the base material is required.

An automatic hair implanter for manufacturing a wig and a method for manufacturing a wig are described in <CIT>. <CIT> discloses a flocking material supplying device for a flocking machine used for making wigs.

An object of the present disclosure is to provide a hair planting apparatus to efficiently plant hairs over a wide area on a base material.

This object is achieved in accordance with the invention by a hair planting apparatus as defined in claim <NUM>. Further preferred embodiments are defined in the dependence claims.

With the above configuration, the present disclosure enables the efficient planting of hair over a wide area on the base material.

A hair planting apparatus <NUM> according to an embodiment of the present disclosure will be described in detail below with reference to the drawings.

<FIG> is a front view illustrating a schematic configuration of the hair planting apparatus <NUM>, <FIG> is a block diagram illustrating a control system of the hair planting apparatus <NUM>, and <FIG> are perspective views of the hair planting apparatus <NUM> seen from different directions respectively.

The hair planting apparatus <NUM> reduces workload and smoothly plants a hair for planting in a base material J.

The hair for planting is not limited to human hair and includes all other fibers similar to human hair, including natural fibers and artificial fibers.

The base material J is not limited to fibrous materials and includes any planar or curved sheet-shaped material, although in the present embodiment, an example of a curved (substantially spherical shell-shaped) sheet that imitates the shape of the top of a human head and that has hexagonal grid-like mesh holes is illustrated. The shape of the mesh hole may not be hexagonal.

As illustrated, the hair planting apparatus <NUM> includes a base stage <NUM> on which the base material J is mounted, a feed device <NUM> that feeds the mounted base material J in one direction (X-axis direction) on its mounting surface and another direction (Y-axis direction) orthogonal to the one direction, a clamp device <NUM> that holds the base material J mounted on the base stage <NUM> from above, a first capture mechanism <NUM> that pulls a hair for planting through a mesh hole on a back side (lower side) of the held base material J to form a small loop, a looper mechanism <NUM> that expands a small loop (see <FIG> and <FIG>), a second capture mechanism <NUM> that pulls the loop on the back side of the hair for planting from a neighboring mesh hole to a surface side (upper side) of the base material J, a third capture mechanism <NUM> that pulls one end of the hair for planting into the loop on the surface side of the hair for planting to form a knot, and a transport mechanism <NUM> that performs a relative transport operation of the held base material J and hook needles of the first to third capture mechanisms <NUM> to <NUM>.

Further, the hair planting apparatus <NUM> includes a camera <NUM> serving as an imaging unit that captures an image of the mounted base material J, a position switch mechanism <NUM> that holds the camera <NUM> and the first capture mechanism <NUM> and switches the positions thereof, a wiper mechanism <NUM> that wipes away to the outside of an upper opening <NUM> the planted hair for planting inserted in the upper opening <NUM> of a clamp plate <NUM> to be described below, an auxiliary clamp mechanism <NUM> that holds the base material J mounted on the base stage <NUM> in an auxiliary manner, a correction mechanism <NUM> for correcting the orientation of the base material J on the base stage <NUM>, a first blower mechanism <NUM> that blows air to orient the hair for planting planted in the base material J in a predetermined direction, a second blower mechanism <NUM> that blows air to push the base material J to the base stage <NUM> side, a control device <NUM> that controls operations of each configuration described above, and a base <NUM> that directly or indirectly supports each configuration described above.

In the following description, the mounting surface on which the base material J is mounted is horizontal, and one side in the Y-axis direction parallel to the mounting surface is referred to as the "left" side and the other side is referred to as the "right" side, while one side in the X-axis direction parallel to the mounting surface is referred to as the "front" side (side close to the paper surface in <FIG>) and the other side is referred to as the "rear" side (side far from the paper surface in <FIG>). Further, the vertical up-and-down direction orthogonal to the X-axis direction and the Y-axis direction is referred to as a Z-axis direction, and one side in the Z-axis direction is referred to as the "upper" side while the other side is referred to as the "lower" side.

Further, the first to third capture mechanisms <NUM> to <NUM> and the looper mechanism <NUM> form a hair planting unit <NUM> that binds the hair for planting to the base material J.

The configurations of the second and third capture mechanisms <NUM> and <NUM> and the looper mechanism <NUM> of the hair planting unit <NUM>, the transport mechanism <NUM>, and the operation of binding the hair for planting to the base material J by the hair planting unit <NUM> and the transport mechanism <NUM> are substantially the same as those disclosed in <CIT>. Reference is made to the present disclosure for detailed descriptions, which are therefore omitted herein.

As illustrated in <FIG>, the base <NUM> is a flat plate body that directly or indirectly supports the entire configuration of the hair planting apparatus <NUM>. An upper surface of the base <NUM> is horizontal in a state when the hair planting apparatus <NUM> is installed on the horizontal surface.

The first capture mechanism <NUM>, the second capture mechanism <NUM>, the position switch mechanism <NUM> supporting the third capture mechanism <NUM> and the camera <NUM>, the looper mechanism <NUM>, the wiper mechanism <NUM>, the auxiliary clamp mechanism <NUM>, the correction mechanism <NUM>, and the first blower mechanism <NUM> described above are directly supported on the base <NUM>.

When elements are said to be "directly supported," it means that the elements are installed without having any transport mechanism provided therebetween, and thus, not to be moved in position in plan view.

As illustrated in <FIG> and <FIG>, the transport mechanism <NUM> includes an X-axis stage <NUM> installed on the upper surface of the base <NUM> and a Y-axis stage <NUM> installed on the X-axis stage <NUM>.

The X-axis stage <NUM> includes a stage plate <NUM> having an upper surface parallel to the X-Y plane, a slide guide <NUM> slidably supporting the stage plate <NUM> in the X-axis direction with respect to the base <NUM>, and a linear transport mechanism (not shown) that allows any transport and positioning of the stage plate <NUM> in the X-axis direction. The linear transport mechanism includes a ball screw mechanism, and an X-axis motor <NUM> including a servomotor which serves as a drive source of the ball screw mechanism.

The Y-axis stage <NUM> includes a stage plate <NUM> having an upper surface parallel to the X-Y plane, a slide guide <NUM> slidably supporting the stage plate <NUM> in the Y-axis direction with respect to the stage plate <NUM> of the X-axis stage <NUM>, and a linear transport mechanism (not shown) that allows any transport and positioning of the stage plate <NUM> in the Y-axis direction. The linear transport mechanism includes a ball screw mechanism, and a Y-axis motor <NUM> including a servomotor which serves as a drive source of the ball screw mechanism.

The base stage <NUM>, the feed device <NUM>, the clamp device <NUM>, and the second blower mechanism <NUM> are directly supported on the stage plate <NUM> of the Y-axis stage <NUM>.

The transport mechanism <NUM> can position the base material J on the base stage <NUM> at any position in the X-Y plane by the cooperation between the X-axis stage <NUM> and the Y-axis stage <NUM>.

The linear transport mechanism of the X-axis stage <NUM> and Y-axis stage <NUM> is not limited to the ball screw mechanism and may be any mechanism that can position the stage plate <NUM> or <NUM> anywhere in the X-axis direction or the Y-axis direction. For example, the linear transport of the stage plate <NUM> or <NUM> may be implemented by a configuration of a pinion-rack mechanism and a servomotor, or the stage plate <NUM> or <NUM> may be linearly transported by a linear motor.

<FIG> is a plan view of the base stage <NUM>, and <FIG> is a perspective view.

As illustrated, the base stage <NUM> includes a base plate <NUM> supported by four posts <NUM> (one is not shown in the drawing) erected on the Y-axis stage <NUM> of the transport mechanism <NUM>, a tower-like erected part <NUM> provided on the upper surface of the base plate <NUM>, and a mounting plate <NUM> serving as a mounting portion provided at an upper end of the erected part <NUM>.

The erected part <NUM> is erected at a center portion of the base plate <NUM> in the plan view.

The mounting plate <NUM> provided at the upper end of the erected part <NUM> is a substantially rectangular frame-like body, and includes a work opening <NUM> in a substantially rectangular shape formed in the center portion. Further, an upper surface of the mounting plate <NUM> is a mounting surface parallel to the X-Y plane.

During the hair planting operation, the base material J is mounted on the mounting surface which is the upper surface of the mounting plate <NUM>. The mounting plate <NUM> is smaller than the base material J, and the base material J is mounted with the lower surface portion thereof being in partial contact with the mounting plate <NUM>. When the binding operation of the hair for planting to the base material J is performed, it is necessary to insert a hook needle of the first capture mechanism <NUM> from the lower side of the base material J into the mesh hole, but the insertion of the hook needle is performed through the work opening <NUM> of the mounting plate <NUM>. Further, the operation of binding the hair for planting by the second and third capture mechanisms <NUM> and <NUM> is also performed within the range of the work opening <NUM> of the mounting plate <NUM>.

As illustrated in <FIG> and <FIG>, the feed device <NUM> includes, on the base plate <NUM> of the base stage <NUM>, a pair of X-axis roller mechanisms <NUM>, <NUM> disposed on both sides of the mounting plate <NUM> in the X-axis direction in a plan view, and a pair of Y-axis roller mechanisms <NUM>, <NUM> disposed on both sides of the mounting plate <NUM> in the Y-axis direction in a plan view.

Each of the X-axis roller mechanisms <NUM> includes a roller <NUM> contacting from below the base material J mounted on the mounting surface of the mounting plate <NUM>, an X-axis feed motor <NUM> serving as a rotational drive source of the roller <NUM>, a support bracket <NUM> supporting the roller <NUM> and the X-axis feed motor <NUM>, two slide guides <NUM> movably supporting the support bracket <NUM> on the base plate <NUM> up and down in the Z-axis direction, two coil springs <NUM> serving as elastic members to urge the support bracket <NUM> upward, and a retraction air cylinder <NUM> pulling the support bracket <NUM> downward against the coil springs <NUM>.

The X-axis feed motor <NUM> supported by the support bracket <NUM> imparts a feed rotation from an output shaft to a rotating shaft of the roller <NUM>, by a transmission mechanism including a pulley and a timing belt. The output shaft of the X-axis feed motor <NUM> and the rotating shaft of the roller <NUM> are both disposed in the Y-axis direction. Therefore, when the roller <NUM> performs rotational driving in contact with the base material J from below, mounted on the mounting surface of the mounting plate <NUM>, the base material J can be fed in the X-axis direction.

Each of the Y-axis roller mechanisms <NUM> includes a roller <NUM> contacting the base material J from below, mounted on the mounting surface of the mounting plate <NUM>, a Y-axis feed motor <NUM> serving as a rotational drive source of the roller <NUM>, a support bracket <NUM> supporting the roller <NUM> and the Y-axis feed motor <NUM>, a slide guide <NUM> movably supporting the support bracket <NUM> on the base plate <NUM> up and down in the Z-axis direction, coil springs <NUM> serving as elastic members to urge the support bracket <NUM> upward, and a retraction air cylinder <NUM> pulling the support bracket <NUM> downward against the coil springs <NUM>.

The Y-axis feed motor <NUM> supported by the support bracket <NUM> imparts the feed rotation from the output shaft to the rotating shaft of the roller <NUM>, by a transmission mechanism including a pulley and a timing belt. The output shaft of the Y-axis feed motor <NUM> and the rotating shaft of the roller <NUM> are both disposed in the X-axis direction. Therefore, when the roller <NUM> performs rotational driving in contact with the base material J from below, mounted on the mounting surface of the mounting plate <NUM>, the base material J can be fed in the Y-axis direction.

When the retraction air cylinders <NUM> and <NUM> are not pulling the support brackets <NUM> and <NUM> downward and the coil springs <NUM> and <NUM> are urging the support brackets <NUM> and <NUM> to the top position, the height of the upper ends of the respective rollers <NUM> and <NUM> is respectively set so as to match the height of the mounting surface (upper surface) of the mounting plate <NUM> or be slightly lower than the mounting surface of the mounting plate <NUM>. The respective rollers <NUM> and <NUM> at this height are at a "feed position" respectively.

In contrast, when the retraction air cylinders <NUM> and <NUM> are pulling the support brackets <NUM> and <NUM> downward, the height of the upper ends of the respective rollers <NUM> and <NUM> is respectively lowered to a height at which the lower surface of the base material J mounted on the mounting plate <NUM> is not reached and feed operation cannot be performed. The respective rollers <NUM> and <NUM> at this height are at a "retraction position" respectively.

When the pair of X-axis roller mechanisms <NUM> is set at the feed position, and the pair of Y-axis roller mechanisms <NUM> is set at the retraction position, and the rollers <NUM> of the pair of X-axis roller mechanisms <NUM> are driven to rotate in the same direction, a transport force in the X-axis direction can be imparted to the base material J from both sides of the mounting plate <NUM>.

Further, when the pair of Y-axis roller mechanisms <NUM> is set at the feed position, and the pair of X-axis roller mechanisms <NUM> is set at the retraction position, and the rollers <NUM> of the pair of Y-axis roller mechanisms <NUM> are driven to rotate in the same direction, a transport force in the Y-axis direction can be imparted to the base material J from both sides of the mounting plate <NUM>.

Thus, the X-axis roller mechanisms <NUM> and the Y-axis roller mechanisms <NUM> perform the transport in the X-axis direction and the transport in the Y-axis direction separately rather than simultaneously.

Further, when the rollers <NUM> of the pair of X-axis roller mechanisms <NUM> at the feed position are driven to rotate reversely in a direction of separating the base material J apart, the tension in the X-axis direction is imparted to the base material J on the mounting plate <NUM> such that slack can be suppressed.

Further, when the rollers <NUM> of the pair of Y-axis roller mechanisms <NUM> at the feed position are driven to rotate reversely in a direction of separating the base material J apart, the tension in the Y-axis direction is imparted to the base material J on the mounting plate <NUM> such that slack can be suppressed.

Hereinafter, the operation control of imparting tension to the base material J in each direction by the pair of X-axis roller mechanisms <NUM> or the pair of Y-axis roller mechanisms <NUM> is referred to as "tension imparting control".

During the hair planting operation of binding the hair for planting to the base material J, the transport mechanism <NUM> described above is used for transporting the base material J together with the mounting plate <NUM>, and positioning each mesh hole of the base material J in the range of the work opening <NUM> with respect to the hook needles of the first to third capture mechanisms <NUM> to <NUM>.

In contrast, the feed device <NUM> is used for transporting the base material J with respect to the mounting plate <NUM> and shifting the range of the base material J facing the work opening <NUM> of the mounting plate <NUM> to another position in the base material J.

Therefore, the transport of the base material J by the transport mechanism <NUM> is finely controlled by a very small amount of transport compared with the transport of the base material J by the feed device <NUM>.

While the configuration in which the roller mechanisms <NUM> and <NUM> in two intersecting directions respectively perform the feed in the X-axis direction and the Y-axis direction orthogonal to each other is illustrated herein, aspects are not limited thereto, and the configuration in which the feed is performed in two diagonally intersecting directions is also possible.

The base stage <NUM> includes a cover member <NUM> covering the base stage <NUM> and the feed device <NUM>. The cover member <NUM> has a substantially convex polyhedron shape with an upper end thereof protruding upward, and the center of the upper end is widely notched such that the upper portions of the rollers <NUM> and <NUM> and the mounting plate <NUM> are respectively exposed upward therethrough. The upper end of the base stage <NUM> may have a polyhedral shape similar to a spherical shell or may have a substantially spherical shell shape.

With the presence of the cover member <NUM>, the base material J mounted on the mounting plate <NUM> is prevented from a direct contact with the configurations other than the respective rollers <NUM> and <NUM> of the feed device <NUM> or with the corners of the base plate <NUM>, allowing a smooth feed operation of the base material J by the feed device <NUM>.

The cover member <NUM> is omitted in drawings other than <FIG>.

As illustrated in <FIG> and <FIG>, the clamp device <NUM> includes a clamp plate (clamp member) <NUM> including a flat plate body elongated in the Y-axis direction above the base stage <NUM>, a pair of support bases <NUM> erected on the upper surface of the stage plate <NUM> of the Y-axis stage <NUM> to individually support both ends of the clamp plate <NUM>, a slide guide <NUM> that allows lifting and lowering of the clamp plate <NUM> with respect to each support base <NUM>, a clamp air cylinder <NUM> serving as an elevating part that lifts and lowers the clamp plate <NUM>, and a coil spring <NUM> provided between each support base <NUM> and the clamp plate <NUM> and serving as an elastic member urging the clamp plate <NUM> upward.

Since the clamp device <NUM> is supported on the stage plate <NUM> of the Y-axis stage <NUM>, the transport mechanism <NUM> transports the clamp device <NUM> together with the base stage <NUM> in the X-Y plane.

The clamp plate <NUM> is directly above the work opening <NUM> of the mounting plate <NUM> and has an upper opening <NUM> in substantially the same shape and size as the work opening <NUM>, extending in the up-and-down direction.

The lower surface of the clamp plate <NUM> can be brought into contact with the mounting surface of the mounting plate <NUM> at a lower limit position of the lifting and lowering operation. The clamp plate <NUM> can be lowered to the lower limit position and clamp the base material J mounted on the mounting plate <NUM> from above to fixedly hold the base material J.

Furthermore, at the lower limit position of the lifting operation, the work opening <NUM> and the upper opening <NUM> of the mounting plate <NUM> can be overlapped at substantially the same position in the plan view.

The second and third capture mechanisms <NUM> and <NUM> described above are disposed above the clamp plate <NUM>, and extend the hook needles downward to perform the operations of binding the hair for planting within the range of the work opening <NUM> of the base material J through the upper opening <NUM>.

Further, four contact plates <NUM> individually contacting the outer circumference of the respective rollers <NUM> and <NUM> are provided on four sides of the upper opening <NUM> on the lower surface side of the clamp plate <NUM>. The lower surface of each contact plate <NUM> is positioned lower than the lower surface of the clamp plate <NUM> and contacts the upper portions of the respective rollers <NUM> and <NUM> at a position short of the lower limit position of the lifting and lowering operation of the clamp plate <NUM>. Thus, it is possible to make the base material J on the mounting plate <NUM> properly contact the respective rollers <NUM> and <NUM> by lowering the clamp plate <NUM> to a position short of the lower limit position, and ensure that the feed operation by the pair of X-axis roller mechanisms <NUM> and the pair of Y-axis roller mechanisms <NUM> can be performed properly.

<FIG> are front views of the clamp device <NUM> with the clamp plate <NUM> at different heights respectively.

<FIG> illustrates the clamp plate <NUM> positioned at a lifted position, which is the upper limit of the lifting and lowering operation, by the upward pressure of each clamp air cylinder <NUM>. In this state, the lower surface of the clamp plate <NUM> is separated far away from the mounting surface of the mounting plate <NUM>.

At the lifted position, the base material J on the mounting plate <NUM> is in the unclamped state. Since the clamp plate <NUM> at the lifted position is separated far away from the mounting plate <NUM>, the hair for planting can be swept through a wiper member <NUM> of the wiper mechanism <NUM> to be described below.

Each clamp air cylinder <NUM> is provided with a regulator <NUM> in the supply path from the pneumatic source, and air pressure for lowering the clamp plate <NUM> can be applied to each clamp air cylinder <NUM> in two stages, high and low, by the control of the control device <NUM>.

<FIG> illustrates the clamp plate <NUM> when the downward pressure of each clamp air cylinder <NUM> is low, and <FIG> illustrates the clamp plate <NUM> when the downward pressure of each clamp air cylinder <NUM> is high.

As illustrated in <FIG>, when the downward pressure of each clamp air cylinder <NUM> is low, the lowered clamp plate <NUM> cannot withstand the upward urging force received from the coil springs <NUM> such that a gap d is formed between the lower surface of the clamp plate <NUM> and the mounting surface of the mounting plate <NUM>, and the base material J is restrained by a small or no restraining force of the clamp. The height of the clamp plate <NUM> at this time is referred to as a weak clamp position.

On the other hand, at this weak clamp position, each contact plate <NUM> of the clamp plate <NUM> contacts the respective rollers <NUM> and <NUM> or forms a very narrow gap with respect to the respective rollers <NUM> and <NUM>. Therefore, when the base material J is mounted on the mounting plate <NUM>, the base material J is pressed by each contact plate <NUM> into contact with the respective rollers <NUM> and <NUM> with appropriate contact force such that the feed operation by the pair of X-axis roller mechanisms <NUM> or the pair of Y-axis roller mechanisms <NUM> can be performed properly.

In contrast, as illustrated in <FIG>, when the downward pressure of each clamp air cylinder <NUM> is high, the clamp plate <NUM> can be lowered against the coil springs <NUM> such that the lower surface of the clamp plate <NUM> and the mounting surface of the mounting plate <NUM> can be brought into pressed contract state. Therefore, when the base material J is mounted on the mounting plate <NUM>, the base material J is firmly gripped by the clamp plate <NUM> and the mounting plate <NUM> and fixedly held with a large restraining force. The height of the clamp plate <NUM> at this time is referred to as a strong clamp position.

Further, a lighting device <NUM> is provided on the upper surface of the mounting plate <NUM>. The lighting device <NUM> irradiates illumination light from above the upper opening <NUM> when the camera <NUM>, which will be described below, captures images of the base material J through the work opening <NUM> from below the mounting plate <NUM>. The lighting device <NUM> is in a retracted position at one end side of the clamp plate <NUM> when no image is captured, and is moved directly above the upper opening <NUM> by an actuator (not shown) to perform illumination when the image is captured.

As illustrated in <FIG>, the auxiliary clamp mechanisms <NUM> are provided on both sides of the base stage <NUM> in the X-axis direction. The two auxiliary clamp mechanisms <NUM> are disposed to face two X-axis roller mechanisms <NUM> individually.

Each of the auxiliary clamp mechanisms <NUM> includes an auxiliary clamp plate <NUM> which is tiltable, and an auxiliary clamp air cylinder <NUM> for tilting the auxiliary clamp plate <NUM>.

The auxiliary clamp plate <NUM> is formed in a shape of a flat plate with a base end being tiltably supported about the Y-axis and a tip end contacting the outer circumferential surface of the roller <NUM> of the X-axis roller mechanism <NUM>.

The auxiliary clamp air cylinder <NUM> imparts tilting force in a direction in which the tip end of the auxiliary clamp plate <NUM> contacts the outer circumferential surface of the roller <NUM>. As a result, the base material J mounted on the mounting plate <NUM> is sandwiched and held in position between the X-axis roller mechanism <NUM> and the tip end of the auxiliary clamp plate <NUM>.

For example, the two auxiliary clamp mechanisms <NUM> are provided to press the base material J so as to prevent misalignment between the base material J and the mounting plate <NUM>, when the clamp plate <NUM> of the clamp device <NUM> is in the lifted position where the base material J of the mounting plate <NUM> is released from restraint.

When the base material J is clamped by the two auxiliary clamp mechanisms <NUM>, the base material J is likely to loosen due to the pressing by the tip end of the auxiliary clamp plate <NUM>. In view of this, it is preferable to simultaneously perform the control of applying tension by the pair of X-axis roller mechanisms <NUM> described above.

As illustrated in <FIG> and <FIG>, the wiper mechanism <NUM> is a mechanism for wiping away the hair for planting bound to the base material J.

As described above, the operation of planting hair on the base material J is performed through the work opening <NUM> and the upper opening <NUM> while the base material J is held by the clamp plate <NUM>.

In this case, each hair for planting bound to the base material J protrudes upward of the clamp plate <NUM> through the upper opening <NUM>.

On the other hand, when the planting of the hair for planting is completed in one section in the work opening <NUM> of the mounting plate <NUM> in the base material J, the clamp plate <NUM> is lifted to the weak clamp position and the feed device <NUM> performs the feed operation of the base material J such that an adjacent section is within the work opening <NUM>.

Then, if each hair for planting in the planted state remains inserted in the upper opening <NUM>, it may possibly affect the feed operation of the base material J, the binding operation of the hair for planting in the next section, the image capturing of a new section through the work opening <NUM>, and the like.

Therefore, the clamp plate <NUM> is lifted to the lifted position, and the operation of wiping, with the wiper mechanism <NUM>, the hair for planting bound to the base material J under the clamp plate <NUM> and wiping each hair for planting from the upper opening <NUM> is performed.

The operation of feeding the base material J and the operation of wiping the hair for planting may be performed in a switched order.

As illustrated in <FIG>, the wiper mechanism <NUM> is disposed on a rear right side of the mounting plate <NUM> in the plan view. Further, the wiper mechanism <NUM> is disposed lower than the clamp plate <NUM> at the lifted position and higher than the mounting plate <NUM>.

The wiper mechanism <NUM> includes a rod-shaped wiper member <NUM> for wiping each hair for planting, a telescopic air cylinder <NUM> extending and contracting the wiper member <NUM>, and a wiping air cylinder <NUM> that imparts the wiper member <NUM> forward and backward movement for wiping.

The wiper member <NUM> is a round bar-shaped member formed in the Y-axis direction and extends leftward from the telescopic air cylinder <NUM>.

The telescopic air cylinder <NUM> is supported by the wiping air cylinder <NUM> so that a plunger moving forward and backward is parallel to the Y-axis direction. The plunger of the telescopic air cylinder <NUM> is connected to the wiper member <NUM> in the extending direction thereof and can switch between contracting the wiper member <NUM> rightward and extending the wiper member <NUM> leftward.

In the contracting state, the wiper member <NUM> is positioned to the right of the mounting plate <NUM>, and in the extending state, overlaps the mounting plate <NUM> in the Y-axis direction.

The wiping air cylinder <NUM> is supported by the base <NUM> so that the plunger is parallel to the X-axis direction. Then, it is possible to support the telescopic air cylinder <NUM> at the tip end of the plunger, and move the wiper member <NUM> forward of the mounting plate <NUM> when the plunger is advanced, and backward of the mounting plate <NUM> when the plunger is retracted.

With the above configuration, when binding the hair for planting to one section in the work opening <NUM> of the mounting plate <NUM> is completed and the clamp plate <NUM> is lifted to the lifted position, the wiper mechanism <NUM> advances the wiper member <NUM> by the wiping air cylinder <NUM>, extends the wiper member <NUM> by the telescopic air cylinder <NUM>, and then retracts the wiper member <NUM> by the wiping air cylinder <NUM>.

As a result, the wiper member <NUM> can penetrate between the work opening <NUM> of the mounting plate <NUM> and the upper opening <NUM> of the clamp plate <NUM>, mow off each hair for planting backward and wipe it away from the upper opening <NUM>.

The wiper member <NUM> may take any form as long as the wiper member <NUM> can wipe away the hair for planting. For example, the wiper member <NUM> is not limited to a round bar shape and may take the shape of a plate or a brush.

The first blower mechanism <NUM> includes a nozzle connected to a pneumatic source. As illustrated in <FIG> and <FIG>, the first blower mechanism <NUM> is disposed forward of and slightly above the mounting plate <NUM> and blows air toward the mounting plate <NUM> to the rear obliquely downward.

As described above, the hair for planting collectively wiped backward by the wiper mechanism <NUM> tends to rise above the base material J from the state of being wiped backward due to the elasticity thereof. In this case, when clamping the base material J by the clamp device <NUM> for a new section, there is a concern that the hair for planting may be caught between the mounting plate <NUM> and the clamp plate <NUM>.

For this reason, the first blower mechanism <NUM> blows air to the hair for planting wiped backward by the wiper mechanism <NUM> so that the hair does not rise.

The second blower mechanism <NUM> includes a nozzle connected to a pneumatic source. As shown in <FIG>, the second blower mechanism <NUM> is provided on one and the other ends of the clamp plate <NUM> in the Y-axis direction, and each of the second blower mechanisms <NUM> blows air toward the mounting plate <NUM> side under the clamp plate <NUM>.

These second blower mechanisms <NUM> have a function of blowing air to press the base material J against the cover member <NUM> and the respective rollers <NUM> and <NUM>, when the clamp plate <NUM> is lifted to release the base material J on the mounting plate <NUM> from restraint, and the like.

Further, the second blower mechanisms <NUM> have a function of blowing air toward the downstream side in the feed direction of the base material J to push the hair for planting to the downstream side in the feed direction of the base material J, when the feed device <NUM> feeds the base material J such that the adjacent section in the Y-axis direction is within the work opening <NUM> and the wiper mechanism <NUM> performs the wiping operation.

<FIG> is a perspective view of the camera <NUM>, the first capture mechanism <NUM>, and the position switch mechanism <NUM>, and <FIG> are plan views thereof.

The camera <NUM> captures images of the base material J from below the mounting plate <NUM> through the work opening <NUM>. The camera <NUM> includes an image sensor such as a Charge-Coupled Device (CCD) or a Complementary Metal Oxide Semiconductor (CMOS) and an optical system.

The camera <NUM> is supported by the position switch mechanism <NUM> together with the first capture mechanism <NUM>, and can be switched between a state in which the optical axis of the camera <NUM> is aligned with the center line along the Z-axis direction passing through the center of the work opening <NUM> and a state in which the center line of the hook needle held by the first capture mechanism <NUM> is aligned therewith.

The first capture mechanism <NUM> includes a hook needle <NUM> which is facing upward, a needle bar <NUM> holding the hook needle <NUM> at its upper end, a ball screw <NUM> along the Z-axis direction, a ball nut <NUM>, a lifting block <NUM> that performs a lifting and lowering operation in conjunction with the ball nut <NUM>, and a capture motor <NUM> that serves as a drive source for the lifting and lowering operation of the hook needle <NUM>.

The ball screw <NUM> is supported by a support frame <NUM> of the position switch mechanism <NUM> so as to be rotatable around the Z axis.

The capture motor <NUM> imparts rotational force to the ball screw <NUM> by means of a belt mechanism.

The ball nut <NUM> is supported by the support frame <NUM> via a slide guide so as to be able to perform the lifting and lowering operation, and is moved up and down by the rotation of the ball screw <NUM>.

The ball nut <NUM> includes an interlocking shaft <NUM> extending forward along the X-axis direction, and the lifting block <NUM> incorporates a linear bush into which the interlocking shaft <NUM> is inserted. In addition, the lifting block <NUM> holds the lower end of the needle bar <NUM> fixedly.

With this configuration, in the first capture mechanism <NUM>, the ball screw <NUM> is rotated by driving of the capture motor <NUM>, and the ball nut <NUM> is moved up and down along the ball screw <NUM>.

The lifting block <NUM> is moved up and down together with the ball nut <NUM> by the interlocking shaft <NUM>, and the needle bar <NUM> and the hook needle <NUM> are moved up and down.

At this time, the lifting block <NUM> can slide along the interlocking shaft <NUM> by means of the incorporated linear bushing, such that it can be moved up and down in conjunction with the ball nut <NUM> even when the needle bar <NUM> is moved forward.

The position switch mechanism <NUM> includes the support frame <NUM> fixedly installed on the base <NUM>, a position switch plate <NUM> that supports the camera <NUM> and the needle bar <NUM>, and a position switch air cylinder <NUM> that serves as a drive source for switching the positions of the camera <NUM> and the needle bar <NUM>.

The support frame <NUM> supports the position switch plate <NUM> slidably along the X-axis direction by a slide guide.

The position switch plate <NUM> supports the camera <NUM> and the needle bar <NUM> side by side in the X-axis direction. Further, the position switch plate <NUM> supports the needle bar <NUM> by means of a linear bush so as to be moved up and down along the Z-axis direction.

The position switch air cylinder <NUM> is attached to the support frame <NUM> such that the plunger moves back and forth in the X-axis direction, and the tip end of the plunger is connected to the position switch plate <NUM>.

The position switch mechanism <NUM> includes stoppers <NUM> and <NUM> that contact the position switch plate <NUM> that is slidable along the X axis from both sides in the X-axis direction.

The stopper <NUM> positions the position switch plate <NUM> such that the optical axis of the camera <NUM> supported by the position switch plate <NUM> coincides with the center of the work opening <NUM>, as shown in <FIG>.

In addition, as shown in <FIG>, the stopper <NUM> positions the position switch plate <NUM> such that the center of the hook needle <NUM> of the needle bar <NUM> coincides with the center of the work opening <NUM>.

In this way, the position switch mechanism <NUM> saves space by arranging the camera <NUM> and the first capture mechanism <NUM> in parallel in the X-axis direction, and also meets a need for positioning both the camera <NUM> and the first capture mechanism <NUM> at the same position within the work opening <NUM> in plan view.

In addition, as described above, the position switch mechanism <NUM> is installed directly on the base <NUM> and does not generate movement on the base <NUM>. On the other hand, the mounting plate <NUM> is installed on the base <NUM> via the transport mechanism <NUM>. Therefore, in plan view, the mounting plate <NUM> is relatively movable in the X-axis and the Y-axis directions with respect to the position switch mechanism <NUM>. Therefore, "the center of the work opening <NUM>" refers to the center of the work opening <NUM> in a state in which the mounting plate <NUM> is positioned at the center of the movable range of the transport mechanism <NUM> (as the reference position of the mounting plate <NUM>).

The base material J is a mesh material developed with mesh holes aligned on its surface. For example, the base material J of this embodiment includes aligned hexagonal mesh holes. When the hair for planting is sequentially bound to each mesh hole of the base material J, the arrangement direction of the mesh holes is held on the mounting plate <NUM> so as to be parallel to the X-axis or Y-axis directions, which is the feed direction of the feed device <NUM>.

However, the alignment direction of the mesh holes may be tilted due to a variety of factors, such as when displacement occurs due to slipping of the base material J during feeding, when the base material J is not flat but has a three-dimensional shape or is made of a soft material that is easily deformable, and the like.

The tilting of the mesh holes of the base material J can be detected from the image captured by the camera <NUM>.

Then, when the tilting of the mesh holes of the base material J exceeds the allowable value, the orientation of the base material J on the base stage <NUM> can be corrected by rotating the camera <NUM> around the Z-axis by the correction mechanism <NUM>.

The correction mechanism <NUM> is arranged in front of the mounting plate <NUM>, as shown in <FIG>. Then, the correction mechanism <NUM> includes a support shaft <NUM> rotatably supported around the Z-axis by a bracket <NUM> installed on the base <NUM>, an arm <NUM> fixed to the upper end of the support shaft <NUM>, a disc-shaped pressing plate <NUM> provided at the tip end of the arm <NUM>, a correction motor <NUM> (see <FIG>) that rotates the pressing plate <NUM> via a belt mechanism, and an arm turning air cylinder <NUM> (see <FIG>) that imparts rotational motion to the support shaft <NUM>.

The support shaft <NUM> is supported along the Z-axis direction by the bracket <NUM>.

The arm <NUM> is connected to the support shaft <NUM> via a spline nut <NUM>. That is, the arm <NUM> can be moved along the support shaft <NUM> and rotated around the Z-axis together with the support shaft <NUM> by the spline nut <NUM>.

In addition, the arm <NUM> is pressed upward by an elastic member, that is, by a coil spring <NUM> via the spline nut <NUM>.

The pressing plate <NUM> provided on the lower surface side of the tip end of the arm <NUM> is rotatably supported with respect to the arm <NUM> around the Z-axis. The pressing plate <NUM> is imparted with rotational motion from the correction motor <NUM> by a belt mechanism provided on the upper surface side of the arm <NUM>. Further, the lower surface side of the pressing plate <NUM> contacts the base material J mounted on the base stage <NUM> from above, so that the rotation of the pressing plate <NUM> can be transferred to the base material J.

In addition, the arm <NUM> is always pressed upward by the coil spring <NUM>, thereby keeping the pressing plate <NUM> at a height away from the base material J on the base stage <NUM>.

A pressing air cylinder <NUM> for lowering the arm <NUM> against the coil spring <NUM> is arranged in parallel with the arm <NUM>, and when correction is performed by rotating the base material J, the pressing plate <NUM> can be lowered to contact the base material J on the mounting plate <NUM>.

Further, the arm turning air cylinder <NUM> inputs rotational motion to the support shaft <NUM> via a link member (not shown) provided at the lower end of the support shaft <NUM>.

By the rotational motion input from the arm turning air cylinder <NUM>, the arm <NUM> can move the pressing plate <NUM> between a retraction position in front of the mounting plate <NUM> and a pressing position directly above the mounting plate <NUM>.

As shown in <FIG>, the control device <NUM> of the hair planting apparatus <NUM> includes a Read Only Memory (ROM) <NUM> storing a program for controlling the hair planting operation, a Random Access Memory (RAM) <NUM> serving as a work area for arithmetic processing, a non-volatile data memory <NUM> which is storage means for storing various setting data or the like and to which the setting data can be rewritten, and a Central Processing Unit (CPU) <NUM> for executing programs in the ROM <NUM>.

The CPU <NUM> is also connected to the first to third capture mechanisms <NUM> to <NUM>, the looper mechanism <NUM>, and the transport mechanism <NUM> that form the hair planting unit <NUM>.

Each of the first to third capture mechanisms <NUM> to <NUM> includes an air cylinder, and the CPU <NUM> controls the operations of the mechanisms through electromagnetic valves (not shown).

The looper mechanism <NUM> includes an actuator, and the CPU <NUM> controls the operation of the looper mechanism <NUM> through a drive circuit (not shown) that operates the actuator.

The transport mechanism <NUM> includes the X-axis stage <NUM> and the Y-axis stage <NUM>, and the CPU <NUM> controls the operations of the X-axis stage <NUM> and the Y-axis stage <NUM> through a drive circuit (not shown) that operates the X-axis motor <NUM> of the X-axis stage <NUM> and the Y-axis motor <NUM> of the Y-axis stage <NUM>.

The CPU <NUM> is connected to the position switch mechanism <NUM> and controls the position switch air cylinder <NUM> through an electromagnetic valve (not shown).

The CPU <NUM> is connected to the X-axis roller mechanism <NUM>, controls the X-axis feed motor <NUM> through a drive circuit (not shown), and controls the retraction air cylinder <NUM> through an electromagnetic valve (not shown).

Similarly, the CPU <NUM> is connected to the Y-axis roller mechanism <NUM>, controls the Y-axis feed motor <NUM> through a drive circuit (not shown), and controls the retraction air cylinder <NUM> through an electromagnetic valve (not shown).

It is to be noted that although two X-axis roller mechanisms <NUM> and two Y-axis roller mechanisms <NUM> are provided, <FIG> shows only one of them, respectively.

The CPU <NUM> is connected to the clamp device <NUM>, controls the clamp air cylinder <NUM> through an electromagnetic valve (not shown), and controls the strength of the air pressure supplied to the clamp air cylinder <NUM> with the regulator <NUM>.

The CPU <NUM> is connected to the lighting device <NUM>, switches ON/OFF of illumination light irradiation, and controls an actuator to move the lighting device <NUM> to a predetermined position.

The CPU <NUM> is connected to the wiper mechanism <NUM> and controls the telescopic air cylinder <NUM> and the wiping air cylinder <NUM> through electromagnetic valves (not shown) connected to each thereof.

The CPU <NUM> is connected to the auxiliary clamp mechanism <NUM> and controls the auxiliary clamp air cylinder <NUM> through an electromagnetic valve (not shown).

It is to be noted that although two auxiliary clamp mechanisms <NUM> are provided, only one is shown in <FIG>.

The CPU <NUM> is connected to the correction mechanism <NUM>, controls the correction motor <NUM> through a drive circuit (not shown), and controls the arm turning air cylinder <NUM> and the pressing air cylinder <NUM> through electromagnetic valves (not shown) connected to each thereof.

Both the first blower mechanism <NUM> and the second blower mechanism <NUM> include electromagnetic valves for supplying high-pressure air to the nozzles, and the CPU <NUM> controls each electromagnetic valve to control the discharge of the air.

In addition, the CPU <NUM> is connected to the camera <NUM>.

Furthermore, the CPU <NUM> is connected to a pedal <NUM> for inputting the start of the hair planting operation.

The CPU <NUM> is also connected to an operation panel <NUM> having a function as a display unit for displaying various information and a function as an input unit for performing various inputs.

The CPU <NUM> also includes software modules such as a feed control unit <NUM>, a tension application control unit <NUM>, a state switch control unit <NUM>, a tilt detection unit <NUM>, a correction control unit <NUM>, and the like. It is to be noted that part or all of these software modules may be configured from hardware.

The functions of the software modules described above will be appropriately described in the operation control of the hair planting operation by the hair planting apparatus <NUM> to be described below.

In addition, the CPU <NUM> controls various air cylinders, various motors, various actuators, and the like with electromagnetic valves, drive circuits, interfaces, and the like. However, in the following description, descriptions of the electromagnetic valves, drive circuits, and interfaces will be omitted, and it will simply be described that various air cylinders, various motors, various actuators, and the like are controlled.

A flow chart of <FIG> shows the overall flow of operation control of the hair planting operation executed by the CPU <NUM>.

First, as a preliminary preparation, the CPU <NUM> controls the clamp air cylinder <NUM> of the clamp device <NUM> to move the clamp plate <NUM> to the lifted position, and controls the auxiliary clamp air cylinders <NUM> of the respective auxiliary clamp mechanisms <NUM> to move the auxiliary clamp plates <NUM> to the released position separated from the X-axis roller mechanism <NUM>.

Then, the CPU <NUM> executes a process of base set (step S1).

That is, when the base material J is mounted on the mounting plate <NUM> of the base stage <NUM> and the start of the hair planting operation is input from the pedal <NUM>, the state switch control unit <NUM> supplies low air pressure to the clamp air cylinder <NUM> from the regulator <NUM> and lowers the clamp plate <NUM> to the weak clamp position.

Next, the CPU <NUM> executes a process of tilt detection (step S3).

That is, the CPU <NUM> controls the position switch air cylinder <NUM> of the position switch mechanism <NUM> to position the position switch plate <NUM> such that the optical axis of the camera <NUM> coincides with the center of the work opening <NUM> at the reference position.

Further, the CPU <NUM> controls the lighting device <NUM> to be moved above the upper opening <NUM> and to irradiate illumination light downward.

Further, the camera <NUM> captures an image of the base material J within the range of the work opening <NUM>, and the tilt detection unit <NUM> extracts a plurality of mesh holes developed on the surface of the base material J from the captured image, and detects the center of gravity g of each mesh hole. <FIG> shows an example of an image captured by the camera <NUM>.

As shown in <FIG>, the tilt detection unit <NUM> specifies the center of gravity gc closest to the center of the camera (the optical axis of the camera <NUM>), and further specifies two points of the center of gravity g on each of the upper side and the lower side of the center of gravity gc, which are arranged in a straight line and are arranged adjacent thereto such that the total score is <NUM> points, which is the reference score. In the tilt detection unit, "adjacent" means the state of being adjacent to each other at the shortest interval. In the case of regular polygonal mesh holes such as regular hexagons, for example, the term "closest spacing" refers to the spacing between the centers of gravities of adjacent mesh holes of which sides are in contact with each other.

If there is no particular need to distinguish a specific center of gravity gc or a center of gravity gn to be described below, from the other centers of gravities g, the centers of gravities will be simply referred to as the "center of gravity g".

Then, the tilt detection unit <NUM> obtains the tilt angle θ of the straight line l passing through these five vertically adjacent centers of gravities g with respect to the X-axis direction (vertical direction in the image). This is the tilt of the base material J.

If the tilt angle θ is within the allowable range, it is determined that the base material J is not tilted, and if the tilt angle θ exceeds the allowable value, it is determined that the base material J is tilted.

In addition, there may be cases in which the mesh holes or the centers of gravities are not detected satisfactorily, and only the number of centers of gravities g less than the reference score can be detected. In this cases, the tilt detection unit <NUM> regards the center of gravity gn of the mesh hole adjacent to the mesh hole of the center of gravity gc on one side in the Y-axis direction as a new center of gravity gc, and detects five centers of gravities g including the center of gravity gn adjacent to each other in the X-axis direction to determine the tilt.

In addition, if five centers of gravities g cannot be obtained for the center of gravity gn, acquisition of five centers of gravities g is attempted for the center of gravity gn up to the specified upper limit number of times on both sides of the original center of gravity gc in the Y-axis direction (for example, left and right twice), and if five centers of gravities g are still not obtained, the tilt detection is stopped. In this case, an error may be notified and the hair planting operation may be interrupted, or the process of tilt detection and the next process of correction control may be skipped and the subsequent hair planting operation may be continued. When the operation continues, the hair planting operation is performed with slightly lower accuracy.

Next, the CPU <NUM> executes the process of correction control (step S5). This correction control is performed by the correction control unit <NUM> when it is determined in step S3 that the base material J is tilted. In addition, if it is determined that there is no tilt, the process is skipped.

The correction control by the correction control unit <NUM> is shown in the flowchart of <FIG>.

As illustrated, the correction control unit <NUM> turns off the lighting device <NUM> used for the tilt detection and retracts it from the upper opening <NUM> (step S21).

Next, the correction control unit <NUM> controls the feed device <NUM>, the clamp device <NUM>, and the auxiliary clamp mechanism <NUM> in parallel.

That is, the correction control unit <NUM> controls the retraction air cylinders <NUM> and <NUM> of the pair of X-axis roller mechanisms <NUM> and the pair of Y-axis roller mechanisms <NUM> of the feed device <NUM> to lower the respective rollers <NUM> and <NUM> to the retraction positions (step S23).

In addition, the state switch control unit <NUM> supplies high air pressure to the clamp air cylinder <NUM> from the regulator <NUM>, and lowers the clamp plate <NUM> of the clamp device <NUM> to the strong clamp position to hold the base material J on the mounting plate <NUM> (step S25).

Further, the correction control unit <NUM> controls the auxiliary clamp air cylinders <NUM> of the respective auxiliary clamp mechanisms <NUM> to bring the respective auxiliary clamp plates <NUM> into contact with the rollers <NUM> of the pair of X-axis roller mechanisms <NUM>, thereby auxiliary clamping the base material J (step S27).

Next, the tension application control unit <NUM> performs tension application control on the X-axis feed motors <NUM> of the pair of X-axis roller mechanisms <NUM> to remove slack in the base material J (step S29).

Then, while the base material J is in the auxiliary clamped state, the correction control unit <NUM> controls the clamp air cylinder <NUM> to retract the clamp plate <NUM> to the lifted position (step S31).

Next, the correction control unit <NUM> controls the arm turning air cylinder <NUM> to move the pressing plate <NUM> above the mounting plate <NUM> (step S33), and controls the pressing air cylinder <NUM> to lower the pressing plate <NUM> and hold the base material J from above (step S35).

Further, the correction control unit <NUM> controls the auxiliary clamp air cylinders <NUM> of the respective auxiliary clamp mechanisms <NUM> to release the auxiliary clamping by the respective auxiliary clamp plates <NUM> (step S37), and then controls the correction motor <NUM> to rotate the base material J in the direction for correcting the tilt angle θ detected by the tilt detection unit <NUM> (step S39).

Next, the correction control unit <NUM> controls the auxiliary clamp air cylinders <NUM> of the respective auxiliary clamp mechanisms <NUM> to return the respective auxiliary clamp plates <NUM> to the auxiliary clamping state (step S41). Furthermore, the tension application control unit <NUM> executes tension application control by the X-axis feed motors <NUM> of the pair of X-axis roller mechanisms <NUM> (step S43).

Further, the correction control unit <NUM> controls the pressing air cylinder <NUM> of the correction mechanism <NUM> to raise the pressing plate <NUM> (step S45), and also controls the arm turning air cylinder <NUM> to move the pressing plate <NUM> to the retraction position separated away from the mounting plate <NUM> (step S47).

Then, the state switch control unit <NUM> supplies low air pressure to the clamp air cylinder <NUM> from the regulator <NUM> to lower the clamp plate <NUM> of the clamp device <NUM> to the weak clamp position (step S49).

Further, the correction control unit <NUM> controls the auxiliary clamp air cylinders <NUM> of the respective auxiliary clamp mechanisms <NUM> to release the base material J from the auxiliary clamping by the respective auxiliary clamp plates <NUM> (step S51).

Then, the correction control unit <NUM> controls the retraction air cylinders <NUM> and <NUM> of the pair of X-axis roller mechanisms <NUM> and the pair of Y-axis roller mechanisms <NUM> of the feed device <NUM> to raise the respective rollers <NUM> and <NUM> to the feed position (step S53).

Next, the CPU <NUM> executes the process of hair planting operation (step S7).

In the process of hair planting operation, the CPU <NUM> controls the lighting device <NUM> so as to be moved above the upper opening <NUM> and also irradiate illumination light downward, and cause the camera <NUM> to capture an image of the base material J.

Then, the CPU <NUM> extracts each mesh hole developed in a predetermined section of the base material J, and specifies the binding positions of the hair for planting around all the mesh holes.

Then, the CPU <NUM> retracts the lighting device <NUM> and controls the position switch air cylinder <NUM> of the position switch mechanism <NUM> to position the position switch plate <NUM> such that the center of the hook needle of the first capture mechanism <NUM> coincides with the center of the work opening <NUM> at the reference position.

Then, by controlling the first to third capture mechanisms <NUM> to <NUM>, the looper mechanism <NUM>, and the X-axis motor <NUM> and Y-axis motor <NUM> of the transport mechanism of the hair planting unit <NUM>, a binding operation of hair for planting is performed for each binding position specified by imaging within a predetermined section.

The operations of the first to third capture mechanisms <NUM> to <NUM>, the looper mechanism <NUM>, and the X-axis motor <NUM> and Y-axis motor <NUM> of the transport mechanism of the hair planting unit <NUM> for binding the hair for planting are substantially the same as the hair planting operation disclosed in FIGS. <NUM> to <NUM> of <CIT> described above, and detailed description thereof will be omitted.

Then, when the hair for planting is bound to all binding points in the section, the CPU <NUM> determines whether or not the planting is completed for all sections scheduled for the base material J (step S9), and when planting is completed for all sections, the CPU <NUM> raises the clamp plate <NUM> of the clamp device <NUM> to the lifted position to release the base material J on the mounting plate <NUM> from restraint, and finishes the hair planting operation.

On the other hand, if the hair planting is not completed for all the sections, the CPU <NUM> executes a process of wiper operation (step S11).

First, the CPU <NUM> controls the retraction air cylinders <NUM> and <NUM> of the pair of X-axis roller mechanisms <NUM> and the pair of Y-axis roller mechanisms <NUM> of the feed device <NUM> to lower the respective rollers <NUM> and <NUM> to the retraction positions.

Further, the CPU <NUM> controls the auxiliary clamp air cylinders <NUM> of the respective auxiliary clamp mechanisms <NUM> to bring the respective auxiliary clamp plates <NUM> into contact with the rollers <NUM> of the pair of X-axis roller mechanisms <NUM>, thereby auxiliary clamping the base material J.

Further, the tension application control unit <NUM> performs tension application control on the X-axis feed motors <NUM> of the pair of X-axis roller mechanisms <NUM> to remove slack in the base material J.

Next, the CPU <NUM> controls the clamp air cylinder <NUM> of the clamp device <NUM> to retract the clamp plate <NUM> to the lifted position.

Then, the CPU <NUM> advances the wiper member <NUM> with the wiping air cylinder <NUM> of the wiper mechanism <NUM> and extends the wiper member <NUM> with the telescopic air cylinder <NUM>. Then, by moving the wiper member <NUM> backward by the wiping air cylinder <NUM>, the wiper member <NUM> wipes backward the hair for planting that extends upward from the base material J and is inserted into the upper opening <NUM> so as to be wiped away from the upper opening <NUM>. The wiper member <NUM> moved backward is returned to the contracting state by the telescopic air cylinder <NUM>.

In addition, when the wiper member <NUM> is completely wiped away, the CPU <NUM> causes the first blower mechanism <NUM> to blow air backward, thereby preventing the hair for planting from standing back up from the backwardly blown state due to the restoring force.

Further, when the feed direction of the base material J is along the Y-axis direction for the movement of the next section, the second blower mechanism <NUM> may blow air toward the downstream side of the base material J in the feed direction to push the hair for planting to the downstream side in the feed direction.

Then, the state switch control unit <NUM> supplies low air pressure to the clamp air cylinder <NUM> from the regulator <NUM> to lower the clamp plate <NUM> of the clamp device <NUM> to the weak clamp position.

The correction control unit <NUM> controls the auxiliary clamp air cylinders <NUM> of the respective auxiliary clamp mechanisms <NUM> to release the base material J from the auxiliary clamping by the respective auxiliary clamp plates <NUM>.

Next, the CPU <NUM> executes a process of feed control (step S13). This feed control is performed by the feed control unit <NUM>.

The feed control unit <NUM> first controls the retraction air cylinders <NUM> or <NUM> of the pair of X-axis roller mechanisms <NUM> or the pair of Y-axis roller mechanisms <NUM> of the feed device <NUM> to raise the respective rollers <NUM> or <NUM> to the feed position.

Further, the feed control unit <NUM> controls the X-axis feed motor <NUM> of each X-axis roller mechanism <NUM> or the Y-axis feed motor <NUM> of each Y-axis roller mechanism <NUM> of the feed device <NUM> to feed the base material J in a predetermined section unit for the hair planting operation. For example, when a square or rectangular section that fits within the range of the work opening <NUM> is set, and the hair planting within the range of the section is completed, the feed control unit <NUM> executes an operation control to feed the base material J in the X-axis or Y-axis direction by a width corresponding to one section, and to move the base material J to the next section.

When the feed operation to the next section is completed, the state switch control unit <NUM> supplies high air pressure to the clamp air cylinder <NUM> from the regulator <NUM> to lower the clamp plate <NUM> of the clamp device <NUM> to the strong clamp position.

Then, the CPU <NUM> returns the process to step S3, and executes the tilt detection, the correction control, the hair planting operation, and the like for the new section.

As described above, the hair planting apparatus <NUM> includes the X-axis roller mechanism <NUM> for feeding the base material J to the mounting plate <NUM> in the X-axis direction by the rollers <NUM>, and the feed device <NUM> having the Y-axis roller mechanism <NUM> for feeding the base material J to the mounting plate <NUM> in the Y-axis direction by the rollers <NUM>.

Therefore, it is unnecessary to manually perform the operation of reattaching the base material J in order to change the execution area of the operation of planting hair on the base material J with respect to the work opening <NUM> of the mounting plate <NUM>, and the base material J can be efficiently planted over a wide area.

In addition, since the hair planting apparatus <NUM> is provided with the feed control unit <NUM> that feeds the base material J to the feed device <NUM> based on a predetermined unit of sections for the hair planting operation, the hair planting apparatus <NUM> can perform planting according to the predetermined unit of sections, and can uniformly perform the planting a wide area of the base material J.

In addition, since both the X-axis roller mechanism <NUM> and the Y-axis roller mechanism <NUM> of the feed device <NUM> include two rollers <NUM> or two rollers <NUM> arranged with the mounting plate <NUM> interposed therebetween in each feed direction, the base material J can be fed satisfactorily in the positive and reverse directions along the X-axis direction and in the positive and reverse directions along the Y-axis direction, respectively, thereby improving the feeding accuracy and thus enabling the performance of the high-quality planting.

Further, the X-axis roller mechanism <NUM> of the feed device <NUM> includes the X-axis feed motor <NUM> as a drive source for each of two rollers <NUM>, and the Y-axis roller mechanism <NUM> includes the Y-axis feed motor <NUM> as a drive source for each of two rollers <NUM>. The control device <NUM> of the feed device <NUM> includes the tension application control unit <NUM> that controls the respective roller mechanisms <NUM> and <NUM> to rotate the motors of two rollers in directions opposite to each other.

Therefore, tension can be imparted to the base material J to prevent the occurrence of slack, so that the hair for planting can be combined with the base material J with high positional accuracy, thereby enabling the performance of the high-quality planting.

The hair planting apparatus <NUM> also includes the clamp device <NUM> that presses with the clamp plate <NUM> the base material J mounted on the mounting plate <NUM> from above, and the base material J can be clamped and held in position after the feed operation of the base material J is performed by the feed device <NUM>, so that it is possible to perform the hair planting operation while maintaining the position after feeding, and perform satisfactory planting on the base material J over a wide area.

In addition, the clamp device <NUM> includes the state switch control unit <NUM> that controls the height and holding force of the clamp plate <NUM> by means of the regulator <NUM> with respect to the clamp air cylinder <NUM> for lifting and lowering the clamp plate <NUM>, so as to switch the base material between a restraining state and a feed enabled state.

Therefore, according to the feed enabled state of the base material, the clamp plate <NUM> appropriately presses the base material J against the rollers <NUM> and <NUM> of the X-axis roller mechanism <NUM> and the Y-axis roller mechanism <NUM>, respectively, thereby enabling smooth feeding, and feeding the base material J with high accuracy.

Furthermore, by having the base material in the restrained state, it is possible to hold the fed base material J with high accuracy, thereby enabling the performance of the high-quality planting.

In addition, since the hair planting apparatus <NUM> includes the wiper mechanism <NUM> that wipes out the planted hair for planting to the outside of the upper opening <NUM> of the clamp plate <NUM>, the clamp plate <NUM> can prevent the hair for planting from being caught in the upper opening <NUM> when re-clamping, and it is possible to reduce the influence of the hair for planting on the hair planting operation, the feed operation of the base material J, the imaging from the operation opening <NUM>, and the like.

In addition, the hair planting apparatus <NUM> includes the tilt detection unit <NUM> that obtains, from the image captured by the camera <NUM>, an alignment direction of the plurality of mesh holes of the base material J, the correction mechanism <NUM> that changes an orientation of the base material J on the mounting plate <NUM> with respect to the camera <NUM>, and the correction control unit <NUM> that corrects, by the correction mechanism <NUM>, the orientation of the base material J on the mounting plate <NUM> according to the tilt angle of the alignment direction of the plurality of mesh holes of the base material J with respect to the predetermined direction.

Therefore, it is possible to correct the direction of the base material J, which is changed in orientation due to various factors such as the feed operation and the clamp operation by the clamp device <NUM>, to an appropriate orientation, and bind the hair for planting with respect to the base material J with high positional accuracy, thereby enabling the performance of the high-quality planting.

Further, since the correction mechanism <NUM> corrects the orientation by rotating the base material J with respect to the mounting plate <NUM>, the subject of rotation is minimized, thereby enabling the size reduction of the correction mechanism <NUM> and realization of the miniaturization of the entire apparatus.

In addition, the hair planting apparatus <NUM> includes the position switch mechanism <NUM> that switches the positions of the camera <NUM> and the first capture mechanism <NUM> such that the work opening <NUM> of the mounting plate <NUM> is arranged from below.

This eliminates the need to arrange the camera <NUM> and the first capture mechanism <NUM> side by side on the same axis, making it possible to reduce the size of the hair planting apparatus <NUM>.

In addition, since the position switch mechanism <NUM> performs position switching such that the hook needle <NUM> and the optical axis of the camera <NUM> are switched on the same axis, the hair planting apparatus <NUM> can be miniaturized particularly in the direction of the optical axis of the camera <NUM>.

Each embodiment of the present disclosure has been described above. However, the present disclosure is not limited to the above embodiments. For example, in certain embodiments, components that are integrally formed from a single member may be replaced with components that are split into multiple members and coupled or affixed together. In addition, a component configured by connecting a plurality of members may be replaced with a component integrally formed by a single member. Other details shown in the embodiments can be changed as appropriate without departing from the scope of the present disclosure.

In the embodiment described above, the configuration of the correction mechanism <NUM> in which the base material J on the mounting plate <NUM> is held from above and the mounting plate <NUM> is rotated is illustrated, but the correction mechanism <NUM> is not limited thereto.

For example, as shown in <FIG>, instead of the correction mechanism <NUM>, the hair planting apparatus <NUM> may be mounted with another correction mechanism <NUM> for correcting the orientation of the base material J by rotating the mounting plate <NUM> together with the base material J.

The correction mechanism <NUM> will be described in detail below.

The correction mechanism <NUM> can rotate the transport mechanism <NUM> provided between the base <NUM> and the X-axis stage <NUM> and around the Z-axis passing through the center of the work opening <NUM> of the mounting plate <NUM> at the reference position, and the components (base stage <NUM>, and the like) supported by the transport mechanism <NUM>.

Specifically, the correction mechanism <NUM> includes a bearing <NUM> directly provided on the upper surface of the base <NUM> and allows rotation about the Z-axis passing through the center of the work opening <NUM> of the mounting plate <NUM>, a rotation stage <NUM> rotatably supported by the bearing <NUM>, and a rotation mechanism (not shown) that imparts a rotational force to the rotation stage <NUM>. The rotation mechanism includes a drive source such as a servomotor that enables the control device <NUM> to control the rotation angle.

The transport mechanism <NUM> (X-axis stage <NUM> and the Y-axis stage <NUM>), the base stage <NUM> including the mounting plate <NUM>, the wiper mechanism <NUM>, the auxiliary clamp mechanism <NUM>, the first blower mechanism <NUM>, the second blower mechanism <NUM>, the feed device <NUM>, and the clamp device <NUM> are mounted directly or indirectly on the rotation stage <NUM> of the correction mechanism <NUM> and applied with rotational motion around the Z-axis with respect to the base <NUM>.

On the other hand, the first capture mechanism <NUM>, the second capture mechanism <NUM>, the third capture mechanism <NUM>, the position switch mechanism <NUM> that supports the camera <NUM>, and the looper mechanism <NUM> are mounted on the base <NUM> and applied with no rotation by the correction mechanism <NUM>.

When mounting the correction mechanism <NUM> on the hair planting apparatus <NUM>, it is preferable to mount a holding mechanism <NUM> on the base <NUM> to press the base material J on the mounting plate <NUM> from above to restrain the base material J from rotating when the mounting plate <NUM> rotates.

In the holding mechanism <NUM> illustrated, since the correction mechanism <NUM> described above is identical to many members, as for the members common to the correction mechanism <NUM> described above, the names and symbols of the members of the correction mechanism <NUM> described above are used, and redundant explanations are omitted.

The holding mechanism <NUM> includes the support shaft <NUM> rotatably supported around the Z-axis by the bracket <NUM> installed on the base <NUM>, the arm <NUM> fixed to the upper end of the support shaft <NUM>, the pressing plate provided at the tip end of the arm <NUM>, the arm turning air cylinder <NUM> that imparts rotational motion to the support shaft <NUM>, the spline nut <NUM>, the coil spring <NUM>, and the pressing air cylinder <NUM> that lowers the arm <NUM> (see <FIG> and <FIG>).

The holding mechanism <NUM> differs from the correction mechanism <NUM> described above in that the pressing plate is fixedly supported by the arm <NUM> and does not include the correction motor <NUM> for rotating the pressing plate.

In the holding mechanism <NUM>, with the configuration described above, when the base stage <NUM> is rotated by the correction mechanism <NUM>, the pressing plate moved above the mounting plate <NUM> by the arm <NUM> rotated by the arm turning air cylinder <NUM> is lowered by the holding air cylinder <NUM> to hold to prevent the base material J from rotating together with the base stage <NUM>.

The correction control performed by the correction control unit <NUM> on the hair planting apparatus <NUM> including the correction mechanism <NUM> and the holding mechanism <NUM> will be described with reference to the flowchart of <FIG>. The correction control by the correction mechanism <NUM> is performed at the same timing as the correction control shown in step S5 in the flowchart of <FIG> described above.

The tilt detection described above (see step S3 in <FIG>) is performed immediately before the correction control, and the correction control unit <NUM> turns off the lighting device <NUM> used at that time and retracts it from the upper opening <NUM> (step S71).

That is, the correction control unit <NUM> controls the retraction air cylinders <NUM> and <NUM> of the pair of X-axis roller mechanisms <NUM> and the pair of Y-axis roller mechanisms <NUM> of the feed device <NUM> to lower the respective rollers <NUM> and <NUM> to the retraction positions (step S73).

In addition, the state switch control unit <NUM> supplies high air pressure to the clamp air cylinder <NUM> from the regulator <NUM>, and lowers the clamp plate <NUM> of the clamp device <NUM> to the strong clamp position to hold the base material J on the mounting plate <NUM> (step S75).

Further, the correction control unit <NUM> controls the auxiliary clamp air cylinders <NUM> of the respective auxiliary clamp mechanisms <NUM> to bring the respective auxiliary clamp plates <NUM> into contact with the rollers <NUM> of the pair of X-axis roller mechanisms <NUM>, thereby auxiliary clamping the base material J (step S77).

Next, the tension application control unit <NUM> performs tension application control on the X-axis feed motors <NUM> of the pair of X-axis roller mechanisms <NUM> to remove slack in the base material J (step S79).

Then, while the base material J is in the auxiliary clamped state, the correction control unit <NUM> controls the clamp air cylinder <NUM> to retract the clamp plate <NUM> to the lifted position (step S81).

Next, the correction control unit <NUM> controls the arm turning air cylinder <NUM> to move the pressing plate above the mounting plate <NUM> (step S83), and controls the pressing air cylinder <NUM> to lower the pressing plate and hold the base material J from above (step S85).

Furthermore, the correction control unit <NUM> controls the auxiliary clamp air cylinders <NUM> of the respective auxiliary clamp mechanisms <NUM> to release the auxiliary clamping by the respective auxiliary clamp plates <NUM> (step S87), and then controls the drive source of the correction mechanism <NUM> to rotate the rotation stage <NUM> by the same tilt angle θ in the same direction as the tilt angle θ of the base material J detected by the tilt detection unit <NUM> (step S89).

As a result, the base material J is pressed from above by the pressing plate to be restrained from rotating, and the rotation stage <NUM>, the base stage <NUM>, and the mounting plate <NUM> generate rotation by the tilt angle θ. That is, the base stage <NUM> and the mounting plate <NUM> are shifted by the same tilt angle θ as the base material J.

Next, the correction control unit <NUM> controls the auxiliary clamp air cylinders <NUM> of the respective auxiliary clamp mechanisms <NUM> to return the respective auxiliary clamp plates <NUM> to the auxiliary clamping state (step S91). Furthermore, the tension application control unit <NUM> executes tension application control by the X-axis feed motors <NUM> of the pair of X-axis roller mechanisms <NUM> (step S93).

Further, the correction control unit <NUM> controls the pressing air cylinder <NUM> of the holding mechanism <NUM> to raise the pressing plate (step S95).

Then, the correction control unit <NUM> controls the arm turning air cylinder <NUM> to move the pressing plate <NUM> to the retraction position separated from the mounting plate <NUM> (step S97).

Then, the state switch control unit <NUM> supplies low air pressure to the clamp air cylinder <NUM> from the regulator <NUM> to lower the clamp plate <NUM> of the clamp device <NUM> to the weak clamp position (step S99).

Furthermore, the correction control unit <NUM> controls the correction mechanism <NUM> and the auxiliary clamp mechanism <NUM> in parallel.

That is, the correction control unit <NUM> controls the drive source of the correction mechanism <NUM> to rotate the rotation stage <NUM> by the same tilt angle θ as the tilt angle θ of the base material J detected by the tilt detection unit <NUM> in a direction opposite to the direction in which the tilt occurs (step S101).

As a result, the base material J, along with the rotation stage <NUM>, rotates the base stage <NUM> and the mounting plate <NUM> by the tilt angle θ in a direction opposite to the tilting direction, and the state in which the base material J, the base stage <NUM>, and the mounting plate <NUM> are misaligned at the tilt angle θ is eliminated.

In parallel with the operation of the correction mechanism <NUM>, the correction control unit <NUM> controls the auxiliary clamp air cylinder <NUM> of the respective auxiliary clamp mechanisms <NUM> to release from the state of being auxiliary clamped by respective auxiliary clamp plates <NUM> (step S103).

Then, the correction control unit <NUM> controls the retraction air cylinders <NUM> and <NUM> of the pair of X-axis roller mechanisms <NUM> and the pair of Y-axis roller mechanisms <NUM> of the feed device <NUM> to raise the respective rollers <NUM> and <NUM> to the feed position (step S105).

Since the correction mechanism <NUM> rotates the base material J together with the base stage <NUM> to correct the tilt angle, it is possible to perform the correction with higher accuracy.

Claim 1:
A hair planting apparatus (<NUM>) comprising:
a mounting portion (<NUM>) configured to mount a base material (J) where planting is performed, and including a work opening (<NUM>) for planting;
a hair planting unit (<NUM>) for binding hair for planting to the base material (J) in the work opening (<NUM>) of the mounting portion (<NUM>);
a feed device (<NUM>) disposed around the mounting portion (<NUM>) and feeding the base material (J) with at least two rollers (<NUM>, <NUM>) contacting the base material (J) from below,
wherein the feed device (<NUM>) feeds the base material (J) in at least two intersecting directions;
a feed control unit (<NUM>) that controls the feed device (<NUM>) to feed the base material (J) according to a predetermined section unit for hair planting operation.