System for delivering chopped fiberglass strands to a preform screen

• US 6,251,185 B1
• Filed: 04/02/1999
• Issued: 06/26/2001
• Est. Priority Date: 04/02/1999
• Status: Expired due to Fees

• Current Assignee: Molded Fiber Glass Companies
• Original Assignee: Molded Fiber Glass Companies
• Inventors: Hutchinson, Kenneth T., Mollman, Robert E., Morrison, Richard S.
• Primary Examiner(s): Crispino, Richard
• Assistant Examiner(s): Tadesse, Yewebdar T
• Application Number:
  US09/285,332
• Time in Patent Office: 816 Days
• Field of Search: 264/121, 264/109.T, 118/679, 118/681, 118/688, 118/690, 118/308, 901/14, 156/62
• US Class Current: 118/681
• CPC Class Codes: B29B 11/16 comprising fillers or reinforcement non-woven fabrics per se D04H1/00, D04H3/00
• CPC Class Codes: B29C 70/305 Spray-up of reinforcing fibres with or without matrix to form a non-coherent mat in or on a mould B29C41/365, B29C70/32, B29C70/34, B29C70/502, B29C70/508 take precedence; coating a former by spraying plastics B29C41/08

Abstract

A system for placing chopped fiberglass strands onto a preform screen where desired includes a relatively light-weight chopper/feeder unit mounted on the outer end of a robot arm in closely spaced relation to the preform screen for robotically directing the chopped fiberglass strands onto the preform screen where desired with very little loss. Within the chopper/feeder unit is a cutter for chopping the fiberglass strands to the desired length. The cutter is driven by a variable speed motor attached to the chopper/feeder unit. Also attached to opposite sides of the chopper/feeder unit are a pair of air amplifiers that produce a sufficient volume and velocity of air flow around said cutter and through said unit to carry the chopped fiberglass strands away from the cutter and out through a discharge chute onto the preform screen.

Claims

1. A system for delivering chopped fiberglass strands to a preform screen comprising a robot having an articulating arm, and a chopper/feeder unit mounted on an outer end of said arm for movement therewith, said chopper/feeder unit comprising a housing containing a cutter for chopping fiberglass strands fed into said housing into desired lengths, a variable speed motor mounted on said housing for driving said cutter, a discharge chute at an outer end of said housing, and two air amplifiers attached to opposite sides of said housing upstream of said cutter for generating an air stream within said housing to carry the chopped fiberglass strands out through said discharge chute.

2. The system of claim 1 wherein said cutter comprises a rubber cot roll, and a cutter roll pressed tight against said rubber cot roll for chopping the fiberglass strands passing between said rolls, said motor being drivingly connected to one of said rolls.

3. The system of claim 2 further comprising an idler roll pressed tight against said rubber cot roll for pulling the fiberglass strands between said rolls.

4. The system of claim 2 wherein a clearance space between said housing and said rolls produces enough velocity and volume of the air stream generated within said housing by said air amplifiers to carry the chopped fiberglass strands away from said rolls and out through said discharge chute.

5. The system of claim 2 wherein said motor is a hydraulic motor, further comprising an encoder pick-up for measuring the number of revolutions of said cutter roll, a servo valve for controlling hydraulic fluid flow to said hydraulic motor, and a controller for controlling the speed of said cutter roll in proportion to the rate of movement of said robot arm to obtain a controlled distribution of chopped fiberglass strands to a preform screen.

6. The system of claim 2 wherein said motor is a variable speed electric motor, further comprising an encoder pick-up for measuring the number of revolutions of said cutter roll, and a controller for controlling the speed of said cutter roll in proportion to the rate of movement of said robot arm to obtain a controlled distribution of chopped fiberglass strands to a preform screen.

7. The system of claim 1 further comprising a curved air deflector in said housing for deflecting the air stream from said air amplifiers toward and around said cutter.

8. The system of claim 1 further comprising a spray gun mounted on said discharge chute for spraying a binder emulsion onto the chopped fiberglass strands deposited on a preform screen.

9. A system for delivering chopped fiberglass strands to a preform screen comprising a robot having an articulating arm, and a chopper/feeder unit mounted on an outer end of said arm for movement therewith, said chopper/feeder unit comprising a housing containing a cutter for chopping fiberglass strands fed into said housing into desired lengths, a variable speed motor mounted on said housing for driving said cutter, a discharge chute at an outer end of said housing, and an air amplifier attached to said housing for generating an air stream within said housing to carry the chopped fiberglass strands out through said discharge chute, said housing comprising a back housing part attached to said robot arm, a front housing part connected to said back housing part, and a latch mechanism for releasably latching said housing parts together for easy access to said housing parts, said air amplifier being attached to a side of said back housing part upstream of said front housing part, and said motor being attached to a side of said front housing part, said front housing part containing said cutter, and said discharge chute extending forwardly from said front housing part downstream of said cutter.

10. The system of claim 9 further comprising fiberglass roving tubes extending through a top wall of said back housing part for feeding the fiberglass strands through said back housing part to said cutter in said front housing part.

11. A system for delivering chopped fiberglass strands to a preform screen comprising a robot having an articulating arm, a housing attached to an outer end of said arm, a cutter within said housing for chopping fiberglass strands fed into said housing to a desired length, a discharge chute extending from said housing downstream of said cutter, and an air amplifier connected to said housing upstream of said cutter for introducing an air stream into said housing to carry the chopped fiberglass strands away from said cutter and out through said discharge chute onto a preform screen in close proximity to said discharge chute, said housing comprising a first housing part attached to said robot arm and a second housing part connected to said first housing part and releasably latched to said first housing part for gaining easy access to the interior of said housing.

12. The system of claim 11 wherein said second housing part contains said cutter, a variable speed motor is mounted on one side of said second housing part for driving said cutter, and said air amplifier is mounted to said first housing part.

13. The system of claim 12 wherein two air amplifiers are attached to opposite sides of said first housing part, and a curved air deflector is mounted within said first housing part in line with said air amplifiers for deflecting the air stream from said air amplifiers toward and around said cutter within said second housing part.

14. The system of claim 13 further comprising a spray gun attached to said discharge chute for spraying a binder onto the chopped fiberglass strands deposited onto the preform screen.

15. The system of claim 11 wherein said cutter comprises a rubber cot roll, a cutter roll pressed tight against said rubber cot roll, a variable speed motor drivingly connected to one of said rolls, and an idler roll pressed tight against said rubber cot roll for pulling the fiberglass strands entering said housing between said rolls.

16. The system of claim 15 wherein a clearance space is provided between said housing and said rolls to produce enough velocity and volume of the air stream introduced into said housing by said air amplifier to carry the chopped fiberglass strands away from said rolls and out through said discharge chute.

17. The system of claim 15 wherein an air amplifier is attached to each side of said housing upstream of said cutter, and a curved air deflector is mounted within said housing in line with said air amplifiers for deflecting the air stream from said air amplifiers toward and around said cutter.

18. The system of claim 15 further comprising an encoder within said housing for measuring the number of revolutions of said cutter roll, and a programmable logic control unit for controlling the speed of said cutter roll in relation to the rate of movement of said robot arm to obtain a controlled output distribution of chopped fiberglass strands from said system in relation to the speed of movement of said robot arm.