There are many types of N95 masks on the market. The mask machine to be analyzed today looks like this:
I still put the axonometric drawing of the mask machine first, and if you look at it, you can get a rough impression:
Then, mark the entire mask machine according to its procedures, and then analyze them in sequence according to these procedures.
I won’t say more about the working order of the overall equipment, it must be from right to left. Then according to the process, we start to speak in turn.
The first process:
Raw material loading process
N95 masks are generally composed of 3-6 layers of fabric (see the mask image above for details). As you can see, this mask machine can make up to 6 layers of masks. When you need to make a few layers of masks, just put a few rolls of fabric on the rack and leave the rest empty.
First, talk about the path of the fabric
Each roll of fabric passes through the tensioning mechanism, and then passes through the fabric roll support frame to enter the next process. It may sound a little confused, but do n’t worry, I have sorted the path of the fabric, so it looks very intuitive :
Because the upper and lower cloth paths are the same, I only got the upper part.
Second, look at the institutions in this process
1. Fabric roll placing rack
This organization will not elaborate, because the article that analyzed the disposable mask machine has been introduced in detail before (if there are students who need to know, you can go to my public number to look at that article), the difference with that organization is: This mechanism is powered by a drive motor.
2. Tension mechanism
The fabric roll is connected to the far right of the fabric. As we said above: the fabric roll placement rack is driven, so the function of this tensioning mechanism is to prevent the fabric from being too loose or too tight. The specific principle is as follows:
Let me talk about it first. The function of the counterweight is to reduce the downward pressure of the two rollers on the left side of the rotating rod on the fabric, but it does not exceed their gravity, so in the free state, the tensioning mechanism will rotate in the direction of the two rollers. of.
1) When the material roll starts to be unloaded, because the unwinding speed is faster than the feeding speed during production, the cloth will start to loosen at this time, and the roller on the left side of the rotating rod starts to fall due to gravity until the sensor plate is detected by the sensor At this point, the drive motor of the cloth roll stops, and the cloth remains tight in the process;
2) When the drive motor stops rotating, the feed will make the fabric more and more tight. At this time, the drum on the left side of the rotating rod will be pulled gradually upward until the sensor board is detected by the sensor above, and the fabric roll begins to unwind;
3) Repeat the above process.
The above is how the tensioning mechanism works. Then, we can see that there is also a hard limit block in the above picture. Its function is to support the rotating rod when the fabric placement frame corresponding to the tensioning mechanism is not used, which is the following state:
Finally, regarding the tensioning mechanism, let me talk about another doubt that everyone may have:
Why is it necessary to tighten the mechanism, can it be removed?
First of all, if there is no tensioning mechanism, the fabric roll needs to be directly connected to the following process, and if so, the following problems must be solved:
1) In order to avoid the problem of too tight or too loose cloth, the front and back speeds need to be matched. Although the production speed of the process is fixed, the rotation speed of the cloth roll can be matched with the process, but the diameter of the cloth roll is not necessarily. When the diameter changes, the discharge speed will also change, so it is very difficult to match the discharge speed and the feed speed;
Therefore, you can see the function of the tensioning mechanism: when there is a lack of material, it can be detected in time and then discharged; when the material is discharged to a certain length, it can also be detected in time and then stopped.
3. Fabric support frame
The fabric support frame mechanism is relatively simple, I will put their detailed pictures on it, everyone will understand it by looking at it:
The second process:
Nasal bridge thread & embossing process
Before talking about the working order of this organization, let ’s talk about the top fabric. We all know that N95 masks are not like disposable masks. You can use folding to wrap the bridge of the nose, so for N95 masks, only the outermost Layer the fabric from above, and insert the bridge of the nose between the fabrics. This is why there is a layer of fabric walking from above.
1. Working sequence
1. The outermost layer and other fabrics respectively enter the embossing mechanism according to the path in the above picture;
2. While the fabric enters the embossing mechanism, the nose bridge thread loading mechanism pushes the nose bridge thread into the fabric.
Second, let’s analyze the organization again
1. Feeding mechanism
The function of this mechanism is to stack several layers of fabric. The principle is actually: the corrugated handle is screwed down, and then the spring presses the sliding block.
The role is relatively simple, so let’s directly talk about its worthy institutions:
First look at the contact mode of the connecting shaft and the fixed block: there is a slot on the connecting shaft to snap into the fixed block, so that the connecting shaft will also move up and down while rotating.
The reason for this is to make it easier to put the fabric between the two rollers when changing the fabric roll: just rotate the handle bar, the upper roller will rise, just put the fabric in.
2. Feeding & loading mechanism of nose bridge line
1) Let’s take a look at the power transmission of the mechanism first. We can see that the power in the above figure is all from the power shaft, and the power of the subsequent processes is basically from the power shaft. Let’s talk about this last.
After the power goes from the power shaft to the top, it is transmitted to the cam divider (the position of the cam divider is marked, and the drawing reports an error, which causes the divider to not be displayed), and then the divider transmits the power to the nose bridge line loading respectively Institutions and feeding institutions.
Then let’s talk about what the original cam divider in this place looks like:
Two input shafts (the other is on that side), one output shaft, the connection mode is: the input shaft is connected to the power and feed mechanism sprocket respectively; the output shaft is connected to the loading mechanism synchronous wheel.
As can be seen from the above picture, the two input shafts are actually a whole, so the power will be directly transmitted to the feeding sprocket, its movement is without intermittent rotation; and the synchronous wheel of the charging mechanism connected to the output shaft passes through the interior of the divider After the mechanism, it becomes intermittent rotation. (If you want to learn more about the splitter, you can Baidu some information)
2) Feeding mechanism of nose bridge line
Let me talk about the specific work order first:
→ The nose bridge line comes out of the material tray and passes through the guiding / driving mechanism (the material tray is unpowered, and the nose bridge line is pulled forward by the driving mechanism);
→ After coming out of the guiding / driving mechanism, go through the material channel and enter the feeding box;
→ After the nose bridge line is put in place, rotate the balance wheel just to touch the cutter to cut the nose bridge line, and then the loading mechanism pushes the nose bridge line into the fabric;
→ Repeat the above process.
After finishing the sequence, let’s analyze the working principle of the nose bridge wire tray and the guiding / driving mechanism:
Nose bridge material tray:
Nose reel-rotating shaft-locking block-ejector rod-pay-off reel, in fact, this set of mechanism is to allow the guiding / driving mechanism to pull out the material when there is a shortage of material; when there is too much material, the reel It can be stopped in time, the specific working principle is as follows:
First of all, we have to know: the nose bridge line is passed under the nose line wheel. When the guiding / driving mechanism is short of material, the nose bridge line is tightened, and then the nose line wheel is lifted up, driving the rotating shaft to rotate, and the rotating shaft again Drive the locking block clockwise, the ejector rod will be lowered, and then the tray can rotate;
When there is more feeding, the nose bridge line will be loose, then the nose line wheel will go down, the remaining action is opposite to the previous one, and finally, the jack will press the pay-off reel, and the reel will stop rotating.
The above is the working principle of the nose bridge material tray.
Then continue to talk about the guiding / driving mechanism
Regarding the lower roller adjustment mechanism, this is the same as the principle and function of the feeding mechanism mentioned above. The difference is that the adjustment screw first tightens the top plate, and then the top plate passes through the spring placed before the roller slider to move the top of the roller. Tight (see the figure below for the specific structure).
Then continue to talk about other institutions. The function of the guiding mechanism is actually to prevent the nose bridge line from deviating. As you can see from the picture, the two rollers on the far left and right are V-shaped, which can restrict the nose bridge line to both sides. Surging
After the nose bridge line comes out of the guiding mechanism, it passes through the sensor mounting block, and then passes through the middle of the pair of roller drums, and enters the rear material channel. The driving cam is the driving cam on the roller, and the cam will contact the roller once every time the cam rotates once.
Note: Some people may ask: Why do you need to use two cams, one can achieve the purpose (in fact, I also thought so at the beginning, hahaha), in fact, its purpose is to use two cams, you can freely Adjust the angle of the contact roller, so that the length of each feed of the bridge line can be adjusted.
3) Nose bridge loading mechanism
Let me talk about it first, there are fisheye connectors at both ends of the putter, but the missing parts are not opened when the model is opened, everyone knows this.
The action sequence of the mechanism is: the rotation of the eccentric wheel drives the push rod and the push plate forward, and the nose bridge line is fed into the middle of the fabric.
3. Embossing mechanism
It can be seen that the power of the embossing mechanism also comes from the power shaft, and this power shaft is the same as the previous power shaft of the nose bridge wire feeding & loading mechanism; and about the specific power transmission between the gears, you can download 3D Look at the model in detail. Next, continue to look at the specific details of this organization:
We look at each station:
Embossing station:
There are many lines on its roller (not expressed on the model), which are used to press out the lines on the outside of the N95 mask.
The reason why the lines can be pressed is because of the following ultrasonic welding head and vibrator. This has been said when analyzing the disposable mask machine, so it will not be wordy;
Regarding the adjustment mechanism of this station, in fact, at a glance, it is clear that: one up and down tightening screw each fixes the sliding block; and the role of the middle spring is for the embossing roller to automatically Lift up without having to unscrew the captive screws below.
Cutting position of breathing valve hole:
The drum has a protruding circle, which is used to cut out the hole where the breathing valve is installed, and the cut waste material is discharged through the hopper. However, there is no station to install the breathing valve behind this mask machine, so this station is not available (in the above video, this station is not used);
Roller to roller mechanism:
Provide the driving force for the advancement of the fabric; as for the function and principle of the upper roller adjustment mechanism, as mentioned above, some students who do not yet understand can turn it forward.
The third process:
Printing process & welding process
The reason why these two processes are mentioned together is because they are related to movement in the actual production process. Let’s take a look at the specific pictures of the two processes:
It can be seen that the left and right earband welding mechanism and the printing mechanism are connected by a screw, and they can move together along the guide rail on the rack. The driving source is the servo motor + screw mechanism under the rack:
And why do the above institutions exercise?
The reason is: the fabric is always in a state of forward movement, and the printing mechanism and the welding ear belt mechanism need to be in contact with the fabric when working. Sporty.
Therefore, the printing mechanism and the welding ear belt mechanism need to advance with the fabric when in contact with the fabric; and return when separated from the fabric.
After explaining the relationship between the institutions and the reasons why the institutions want to move, let’s continue to analyze the institutions one by one.
1. Pad printing process
We often see such text on both sides of N95 masks, which is made by this process.
Next, look at the specific structure of the printing process:
Let me talk about it first, the principle of the left and right printing mechanism is the same; this printing process uses the printing process, and we will talk about the printing process later.
1. The movement of the end seal and the mimeograph box is through the synchronous belt + rail mechanism: the motor drives the synchronous belt wheel movement, and then the sliding mechanism and the synchronous belt are fixed, and linear movement can be done;
This mechanism is relatively simple, but it is very commonly used, so you can remember it and use it to design other equipment in the future.
2. Sequence of actions (actually, the printing process):
1) Apply the paint on the pad of the pad printing box first;
2) The seal moves to the top of the pad, then the biaxial cylinder presses down, and the seal is stained with paint;
3) Finally, the seal is moved above the position where the fabric passes, and the biaxial cylinder is pressed down, and the paint can be printed on the fabric.
Second, the welding process
The welding mechanism and principle of the left and right ear straps are the same, but the positions are different, so let’s analyze one of them.
The whole process is still divided into several institutions, so that we can say more details. Let me talk about the approximate working steps of the whole process:
→ The ear strap comes out of the feeding mechanism and goes to the ear strap to pull the welding mechanism;
→ Then the ear strap pulls the welding mechanism, pulls the ear strap, and then the ear strap mechanism cuts the ear strap;
→ Finally, the welding mechanism is pulled by the ear strap, and the ear strap is welded to the mask.
Well, the general work sequence is like this, and then start to analyze the organization in order:
1. Earband feeding mechanism
This mechanism was originally used on the disposable mask machine, but I forgot to analyze it at the time, so I brought it this time.
The path of the ear strap:
Earband Roller–Drive Wheel & Pressing Wheel–Adjusting Wire Wheel–Threading Wheel–Threading Hole
It can be seen that the pressing wheel presses the ear strap on the driving wheel. As the driving wheel rotates, the ear strap will continue to go down; at the other end, after the ear strap passes through the wire hole, the pulling mechanism is connected. But obviously, the feeding and pulling speed of the ear strap will not match, so the function of adjusting the reel is to adjust the tightness of the ear strap.
When the driving wheel drive ear strap is released, the ear strap will become loose. At this time, the adjustment wire wheel will drop due to gravity until it is detected by the sensor, and the drive motor stops working; at this time, the pulling mechanism will continue to pull the ear strap to adjust The reel is lifted up. When the sensor cannot detect the reel, the drive motor starts to work immediately, so that the ear strap starts to discharge. In this way, this unwinding action is continuously circulated.
2. Ear strap pull welding mechanism
The ultrasonic vibrator and welding head on the left have already been explained, so it is not a nonsense;
Focus on the right side, because the picture may not be very clear, so let’s talk about the connection between some parts:
The pressing cylinder drives the fixed plate; the upper part of the welding rod is threaded and is locked on the fixing plate through the lock nut; the welding rod and the ear strap pulling & processing mechanism can slide relatively (you can see the details of the welding rod end ), But when the welding rod rises to the end contacting the ear strap pulling mechanism, the entire ear strap pulling mechanism will be held up;
The above is the special explanation to be done. Let me talk about the principle of longitudinal motion:
→ Press down the cylinder to drive the fixing plate downward;
→ The fixed plate drives the welding rod downward;
→ At this time, the ear strap pulling mechanism that was originally lifted by the welding rod began to go down due to gravity;
→ When the ear strap pulling mechanism is at the end, pressing down on the cylinder will drive the welding rod to continue downward until the end is at the end.
→ Press down the cylinder to drive the fixing plate upward;
→ The fixing plate drives the welding rod upward until the end touches the ear strap pulling mechanism, and the two start to move upward together;
→ Until it reaches the cylinder limit.
1) Next, we will start to analyze the ear strap pulling & processing mechanism
The above are two different angles of the ear strap pulling & processing mechanism, and then a detailed picture of the end claw:
First explain the role of some parts:
① The sensor detects the motor rotation induction block to cooperate with the motor to control the rotation angle (180 ° for each rotation);
② The shrapnel in the end claw can pass the steel ball to maintain the state of the claw (after being pressed by the pressing claw block, it will not bounce);
③ After the claw is pressed down by the pressing claw block, it will become this state (the ear strap can be pressed tightly to prevent falling):
Then talk about the work order of this organization (most important):
→ In the initial state, one end of the earband passes through the reel and is pressed under the claw-1;
→ At this time, the rotating motor drives the end claw to rotate 180 ° to the right, and the claw-1 will automatically pull the ear strap when it is pressed against the end of the ear strap, and becomes the following state:
→ The claw cylinder drives the claw block to press down, press down the claw, press the ear strap, after the ear strap mechanism cuts the ear strap, and retracts with the claw block; (The principle of shearing will be described later)
→ Then, the whole mechanism starts to press down, until the crimping blocks on both sides press the ends of the ear straps;
→ After the crimping block welds the earband to the mask, the crimping cylinder drives the crimping line to press down. While the crimping line pushes off the earband on the winding block, the crimping line mounting plate will press down Claw-2 & Claw- 3 & Claw-the raised end of the four places, so that the paws of the three places are restored to the original state, and the paw can put the cut ear strap down (note: the paw at the paw-1 is not pressed, so it will not be released );
Note: The pressure line mounting plate will only press the claws at Claw-2 & Claw-3 in the subsequent action, because the state of Claw-4 will be the claws after the restoration (there is a bit of a mouthful, you need to think carefully to understand Up).
→ The whole mechanism rises, and the earband is successfully welded to the mask. By continuously repeating the above process, the action of quickly pulling & welding the ear bands is realized.
3. Ear strap mechanism
The purple part is used to adjust the angle and position of the ear strap mechanism. I have already marked it, so I won’t go into details.
To make a special note: the pin hole of the push block and the rotation axis of the scissors have pins in actual production; the spring is placed in the hole (one on each side), and there should also be a spring, probably because the original author did not add or It is the reason for the error when the model is opened, and it is not displayed. Everyone knows this.
Then there is, there is no connection between the push block and the green parts in the picture and the scissors limit block, and it can slide. The picture may not be very clear, so I remind everyone.
The working order of this institution:
→ The cylinder pushes the front-end mechanism to reach the ear strap;
→ When the scissors stopper hits the pressure claw block introduced above (see the figure below for details), the cylinder continues to push. At this time, the pusher will push the scissors to form a closure, thus cutting the ear strap;
→ When retracting, due to the spring action on the push block, the push block and the scissors limit block are separated, and the scissors return to the open state again.
The above is the working principle of the ear-shearing mechanism. Well, I finally analyzed more than half of the whole device, so tired! ! ! Continue below.
The fourth process:
Labeling process
This labeling mechanism affixes the label on the inside of the mask, but I think there is no label on the inside of the N95 mask. Maybe I have not seen it, but since this organization is here, we will analyze it together.
In fact, this is a standard labeling agency, and friends who have done labeling machines should be familiar with it.
When the fabric passes from above, the labeling mechanism will attach the label to the fabric, and then look at the specific details of the labeling mechanism (note: the adjustment mechanism is a screw, specific details, you can view the three-dimensional model):
Let’s look at the picture from another angle:
First, take a look at the working order of the label paper:
The label tray–passes through the three rollers below–passes between the label stripping plate and the label pressing plate, and at the same time sticks the label on the bottom paper to the mask–the bottom paper passes through the traction mechanism and finally reaches the bottom paper roller on
The forward power of the label paper depends on the pulling of the traction mechanism, and the power of the traction mechanism and the bottom paper roller comes from the motor on the driving wheel.
Let’s take a look at the role of some institutions:
Tension roller: keep the label paper tight, its working principle is as follows:
There is a contraction coil spring at the rotation of the tension roller. When the label paper is loose, the tension roller supports the label paper by the stress of the coil spring, so as to achieve the purpose of keeping the label paper tight.
The role of pushing the cylinder: when labeling is required, push the cylinder to push the peeling plate and the pressing plate onto the mask for labeling; after the labeling, return it.
The fifth process:
Mask cutting & waste disposal process
In this process, the role of the feeding mechanism and the roller mechanism 1-4 are to pull the mask forward, and their driving force comes from the power shaft (this power shaft is the same as the previous one), and the specific power transmission method, You can download the three-dimensional model to study in detail; the principles and functions of the adjustment mechanism of these mechanisms have been mentioned before. If you do n’t see it, you can turn it up and it wo n’t be wordy here.
1. Then the mask folding mechanism:
We all know that N95 masks are folded, and the masks are always spread out in the previous process, so the role of this process is to fold the mask that was originally spread in half, and then enter the pair of roller drum-1.
Second, the non-powered roller station
This station is relatively simple, but its adjustment method can be said:
Turn the corrugated handle to drive the transmission shaft to rotate, and then drive the screw to rotate through the umbrella gear transmission mechanism, so as to achieve the purpose of adjusting the position of the movable roller.
3. Mask cutting station
The screw drive module drives the entire mechanism to reciprocate, and its purpose is the same as the previous one, to ensure that there is no relative displacement with the mask;
The folded mask is heated by cutting the embossing mold and ultrasonic to achieve the purpose of cutting the mask.
Fourth, turn the ear belt station
Before passing the ear strap station, the ear straps are facing down, and we can see from the video above that when the mask comes out, the ear straps are facing up. The ear straps of the mask turned over.
5. Mask output station
The discharge belt takes the mask out, and the scraps that have been cut off are taken from the following path: roller-1 → roller-2 → roller 3 → roller 4 → driving roller & pressing roller, and are discharged.
The power of the waste collection mechanism is also the same power shaft, which is transmitted through the umbrella tooth mechanism. Let’s take a look at the power shaft with the most appearances, and where does its power come from:
It can be seen that the power source is two servo motors + reducer, and then their power is transmitted to each process through a power shaft.
The whole equipment is composed of several racks, so in order to not remove the entire power shaft when separating the racks, the cross universal joint in the picture is used at the place where the racks are docked Shaft (standard parts):
It’s finally over! ! The above is the movement and mechanism analysis of the N95 automatic mask machine. It is still that sentence. If there is something that has not been mentioned, you are welcome to add it in the comment area.