HAIR PLANTING APPARATUS

Abstract

A hair planting apparatus includes a base support mechanism that supports a base material, a hair holding mechanism that holds hair for planting on one side of the base material, and a hair planting part that knots the held hair for planting to the base material by hook needles. The hair holding mechanism includes a first gripping mechanism and a second gripping mechanism that individually grip the hair for planting, and the first gripping mechanism includes two sliding plates that slidably grip the hair for planting, an elastic body that applies gripping pressure to the two sliding plates, and a release mechanism that opens the two sliding plates to release the hair for planting.

Claims

1. A hair planting apparatus comprising: a base support mechanism configured to support a base material; a hair holding mechanism configured to hold hair for planting on one side of the supported base material; a hair planting unit configured to knot the hair for planting held by the hair holding mechanism to the base material using a hook needle, in which the hair holding mechanism includes a first gripping mechanism and a second gripping mechanism configured to individually grip the hair for planting, and the first gripping mechanism comprises two sliding plates configured to slidably grip the hair for planting, an elastic body configured to apply gripping pressure to the two sliding plates, and a release mechanism configured to open the two sliding plates to release the hair for planting.

2. The hair planting apparatus according to claim 1, wherein the release mechanism comprises an insertion plate configured to be inserted between the two sliding plates.

3. The hair planting apparatus according to claim 2, wherein the insertion plate has a function of discharging the hair for planting present between the two sliding plates.

4. The hair planting apparatus according to claim 1, further comprising a detection device configured to detect the hair for planting gripped by the two sliding plates of the first planting mechanism.

5. The hair planting apparatus according to claim 4, further comprising a control device configured to open the two sliding plates by the release mechanism to release the hair for planting when the detection device detects the hair for planting after a hair planting operation.

6. The hair planting apparatus according to claim 5, wherein when the detection device detects the hair for planting after the hair planting operation by the hair planting unit, the control device executes a retry of the hair planting operation.

7. The hair planting apparatus according to claim 1, further comprising a recovery device configured to recover the hair for planting from the two sliding plates.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0015] FIG. 1 is a front view showing a schematic configuration of a hair planting apparatus that is an embodiment of the invention.

[0016] FIG. 2 is a block diagram showing a control system of the hair planting apparatus.

[0017] FIG. 3 is a perspective view of the hair planting apparatus.

[0018] FIG. 4 is another perspective view of the hair planting apparatus.

[0019] FIG. 5 is still another perspective view of the hair planting apparatus.

[0020] FIG. 6 is a plan view of a base stage.

[0021] FIG. 7 is a perspective view of the base stage.

[0022] FIG. 8 is a front view of a clamp device with a clamp plate at a lifted position.

[0023] FIG. 9 is a front view of the clamp device with the clamp plate at a weak clamp position.

[0024] FIG. 10 is a front view of the clamp device with the clamp plate at a strong clamp position.

[0025] FIG. 11 is a perspective view of a hair supply device and a hair holding mechanism.

[0026] FIG. 12 is a right side view of the hair supply device and the hair holding mechanism.

[0027] FIG. 13 is a perspective view of the hair holding mechanism.

[0028] FIG. 14 is a plan view of the hair holding mechanism.

[0029] FIG. 15 is an explanatory diagram of an operation of the hair holding mechanism in a plan view.

[0030] FIG. 16 is an explanatory diagram of the operation of the hair holding mechanism in a plan view following FIG. 15.

[0031] FIG. 17A is an explanatory diagram of a binding operation of hair for planting in a right side view, and FIG. 17B is an explanatory diagram of the binding operation of hair for planting in a rear view.

[0032] FIG. 18A is an explanatory diagram of the binding operation of hair for planting in a right side view, and FIG. 18B is an explanatory diagram of the binding operation of hair for planting in a rear view.

[0033] FIG. 19A is an explanatory diagram of the binding operation of hair for planting in a right side view, and FIG. 19B is an explanatory diagram of the binding operation of hair for planting in a rear view.

[0034] FIG. 20 is a flow chart showing an overall flow of operation control of a hair planting operation.

[0035] FIG. 21 is a flow chart showing control of a supply operation of hair for planting included in a step of hair planting operation.

DESCRIPTION OF EMBODIMENTS

Overall Configuration of Embodiment of Invention

[0036] Hereinafter, a hair planting apparatus 10 according to an embodiment of the present invention will be described in detail with reference to the drawings.

[0037] FIG. 1 is a front view showing a schematic configuration of a hair planting apparatus 10, FIG. 2 is a block diagram showing its control system, and FIGS. 3 to 5 are perspective views of the hair planting apparatus 10 viewed from different directions, respectively.

[0038] The hair planting apparatus 10 is intended to reduce workload and to smoothly plant a hair for planting M into a base material J in order to manufacture a wig or hairpiece.

[0039] The hair for planting M is not limited to human hair, but is intended for all other fibers comparable to human hair, including natural fibers and artificial fibers.

[0040] The base material J is not limited to a fiber shape and includes all sheet-like materials having a planar or curved shape, but in the present embodiment, a sheet having a curved shape (approximately a spherical shell shape) that has hexagonal lattice-like mesh holes and imitates the shape of the crown of the human head will be exemplified. Note that the shape of the mesh hole need not be hexagonal.

[0041] As shown, the hair planting apparatus 10 includes a base stage 30 as a base support mechanism on which the base material J is placed, a feed device 40 that feeds the placed base material J in one direction (referred to as X-axis direction) on the placement surface and another direction (referred to as Y-axis direction) orthogonal to the one direction, a clamp device 50 that holds the base material J placed on the base stage 30 from above, a hair holding mechanism 68 that holds the hair for planting M on one side (e.g., upper surface side) of the base material J supported on the base stage 30, a hair supply device 74 that supplies the hair for planting M to the hair holding mechanism 68, a first capture mechanism 21 that pulls the hair for planting M held in the hair holding mechanism 68 through a mesh hole H1 to a back side (lower side) of the base material J to form a loop, a looper mechanism 24 that expands the loop (see FIGS. 17A to 19B), a second capture mechanism 22 that pulls the loop of the hair for planting M on the back side of the base material J from a neighboring mesh hole H2 to a surface side (upper side) of the base material J, a third capture mechanism 23 that pulls one end portion of the hair for planting M into the small loop of the hair for planting M on the surface side and knots it between the mesh holes H1 and H2, and a moving mechanism 25 that performs a relative movement operation between the base material J and hook needles 211 to 231 of the first to third capture mechanisms 21 to 23.

[0042] Further, the hair planting apparatus 10 includes a camera 11 as an imaging unit that captures an image of the placed base material J, a position switch mechanism 28 that holds the camera 11 and the first capture mechanism 21 and switches their positions, a wiper mechanism 61 that sweeps out the planted hair for planting M inserted in an upper opening 511 of a clamp plate 51 described below to the outside of the upper opening 511, an auxiliary clamp mechanism 62 that holds the base material J placed on the base stage 30 in an auxiliary manner, a correction mechanism 63 that corrects an orientation of the base material J on the base stage 30, a first blower mechanism 64 that blows air to orient the hair for planting M planted in the base material J in a predetermined direction, a second blower mechanism 65 that blows air to press the base material J toward the base stage 30, a control device 100 that controls operations of each configuration described above, a base 12 that directly or indirectly supports each configuration described above, and a cover (not shown) that houses the entire hair planting apparatus 10.

[0043] Note that, in the following description, the placement surface on which the base material J is placed is horizontal, and one side in the Y-axis direction parallel to the placement surface is referred to as the left side, the other side is referred to as the right side, while one side in the X-axis direction parallel to the placement surface is referred to as the front side (side close to the paper surface in FIG. 1), and the other side is referred to as the rear side (side far from the paper surface in FIG. 1). 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 and the other side is referred to as the lower side.

[Base and Moving Mechanism]

[0044] As shown in FIG. 1, the base 12 is a flat plate body that directly or indirectly supports the entire configuration of the hair planting apparatus 10. An upper surface of the base 12 is horizontal in a state in which the hair planting apparatus 10 is installed on the horizontal surface.

[0045] The first capture mechanism 21, the second capture mechanism 22, the position switch mechanism 28 that supports the third capture mechanism 23 and the camera 11, the looper mechanism 24, the wiper mechanism 61, the auxiliary clamp mechanism 62, the correction mechanism 63, and the first blower mechanism 64 described above are directly supported on the base 12.

[0046] Note that the term directly supported means that a configuration is installed without interposition of a mechanism for performing movement and its position in a plan view remains unchanged.

[0047] As shown in FIGS. 1 and 2, the moving mechanism 25 includes an X-axis stage 26 installed on the upper surface of the base 12, and a Y-axis stage 27 installed on the X-axis stage 26.

[0048] The X-axis stage 26 includes a stage plate 261 having an upper surface parallel to the X-Y plane, a slide guide 262 that supports the stage plate 261 to be slidable along the X-axis direction with respect to the base 12, and a linear moving mechanism (not shown) that allows the stage plate 261 to be moved and positioned arbitrarily in the X-axis direction. The linear moving mechanism includes a ball screw mechanism, and an X-axis motor 263 including a servomotor serving as a drive source of the ball screw mechanism.

[0049] The Y-axis stage 27 includes a stage plate 271 having an upper surface parallel to the X-Y plane, a slide guide 272 that supports the stage plate 271 to be slidable along the Y-axis direction with respect to the stage plate 261 of the X-axis stage 26, and a linear moving mechanism (not shown) that allows the stage plate 271 to be moved and positioned arbitrarily in the Y-axis direction. The linear moving mechanism includes a ball screw mechanism, and a Y-axis motor 273 including a servomotor serving as a drive source of the ball screw mechanism.

[0050] The base stage 30, the feed device 40, the clamp device 50, and the second blower mechanism 65 are directly supported on the stage plate 271 of the Y-axis stage 27.

[0051] The moving mechanism 25 can position the base material J on the base stage 30 at any position in the X-Y plane by cooperation of the X-axis stage 26 and the Y-axis stage 27.

[0052] Note that, the linear moving mechanism of each of the X-axis stage 26 and Y-axis stage 27 is not limited to the ball screw mechanism and may be any mechanism that can position the stage plate 261 or 271 at any position along the X-axis direction or the Y-axis direction. For example, the linear moving operation of the stage plate 261 or 271 may be implemented by a configuration of a pinion-rack mechanism and a servomotor, or the stage plate 261 or 271 may be linearly moved by a linear motor.

[Base Stage]

[0053] FIG. 6 is a plan view of the base stage 30, and FIG. 7 is a perspective view.

[0054] As shown, the base stage 30 includes a base plate 32 supported by four support posts 31 (one is not shown in the drawing) erected on the Y-axis stage 27 of the moving mechanism 25, a tower-like erected portion 33 provided on an upper surface of the base plate 32, and a placement plate 34 serving as a placement part provided at an upper end portion of the erected portion 33.

[0055] The erected portion 33 is erected at a central portion of the base plate 32 in a plan view.

[0056] The placement plate 34 provided at the upper end portion of the erected portion 33 is a substantially rectangular frame-like body, and includes a work opening 341 having a substantially rectangular shape and formed in a central portion thereof. In addition, an upper surface of the placement plate 34 is a placement surface parallel to the X-Y plane.

[0057] During a hair planting operation, the base material J is placed and supported on the placement surface that is the upper surface of the placement plate 34. The placement plate 34 is smaller than the base material J, and the base material J is placed with a lower surface portion thereof in partial contact with the placement plate 34. When performing a binding operation of the hair for planting M to the base material J, it is necessary to insert the hook needle of the first capture mechanism 21 into the mesh hole from the lower side of the base material J, but the insertion of the hook needle is performed through the work opening 341 of the placement plate 34. In addition, the binding operation of the hair for planting M by the second and third capture mechanisms 22 and 23 is also performed within the range of the work opening 341 of the placement plate 34.

[Feed Device]

[0058] As shown in FIGS. 6 and 7, the feed device 40 includes, on the base plate 32 of the base stage 30, a pair of X-axis roller mechanisms 41 and 41 arranged on both sides of the placement plate 34 in the X-axis direction in a plan view, and a pair of Y-axis roller mechanisms 42 and 42 arranged on both sides of the placement plate 34 in the Y-axis direction in a plan view.

[0059] Each X-axis roller mechanism 41 includes a roller 411 that comes into contact with the base material J from below, placed on the placement surface of the placement plate 34, an X-axis feed motor 412 serving as a rotational drive source of the roller 411, a support bracket 413 that supports the roller 411 and the X-axis feed motor 412, two slide guides 414 that support the support bracket 413 on the base plate 32 to be movable up and down along the Z-axis direction, two coil springs 415 serving as elastic members to press the support bracket 413 upward, and a retraction air cylinder 416 that pulls the support bracket 413 downward against the coil springs 415.

[0060] The X-axis feed motor 412 supported by the support bracket 413 imparts feed rotation from an output shaft thereof to a rotation shaft of the roller 411 by a transmission mechanism including a pulley and a timing belt. The output shaft of the X-axis feed motor 412 and the rotation shaft of the roller 411 are both arranged along the Y-axis direction. Therefore, when the roller 411 is driven to rotate in contact with the base material J from below, placed on the placement surface of the placement plate 34, the base material J can be fed in the X-axis direction.

[0061] Each Y-axis roller mechanism 42 includes a roller 421 that comes into contact with the base material J from below, placed on the placement surface of the placement plate 34, a Y-axis feed motor 422 serving as a rotational drive source of the roller 421, a support bracket 423 that supports the roller 421 and the Y-axis feed motor 422, a slide guide 424 that supports the support bracket 423 on the base plate 32 to be movable up and down along the Z-axis direction, a coil spring 425 serving as an elastic member to press the support bracket 423 upward, and a retraction air cylinder 426 that pulls the support bracket 423 downward against the coil spring 425.

[0062] The Y-axis feed motor 422 supported by the support bracket 423 imparts feed rotation from an output shaft thereof to a rotation shaft of the roller 421 by a transmission mechanism including a pulley and a timing belt. The output shaft of the Y-axis feed motor 422 and the rotation shaft of the roller 421 are both arranged along the X-axis direction. Therefore, when the roller 421 is driven to rotate in contact with the base material J from below, placed on the placement surface of the placement plate 34, the base material J can be fed in the Y-axis direction.

[0063] In a state in which the retraction air cylinders 416 and 426 are not pulling the support brackets 413 and 423 downward and the coil springs 415 and 425 are pressing the support brackets 413 and 423 to the top position, a height of an upper end portion of each of the rollers 411 and 421 is set to match a height of the placement surface (upper surface) of the placement plate 34 or to be slightly lower than the placement surface of the placement plate 34. Each of the rollers 411 and 421 at the height is at a feed position.

[0064] In contrast, in a state in which the retraction air cylinders 416 and 426 are pulling the support brackets 413 and 423 downward, the height of the upper end portion of each of the rollers 411 and 421 is lowered to a height at which the lower surface of the base material J placed on the placement plate 34 is not reached and a feed operation cannot be performed. Each of the rollers 411 and 421 at the height is at a retraction position.

[0065] When the pair of X-axis roller mechanisms 41 is set at the feed position, the pair of Y-axis roller mechanisms 42 is set at the retraction position, and the rollers 411 of the pair of X-axis roller mechanisms 41 are driven to rotate in the same direction, a conveying force in the X-axis direction can be applied to the base material J from both sides of the placement plate 34.

[0066] In addition, when the pair of Y-axis roller mechanisms 42 is set at the feed position, the pair of X-axis roller mechanisms 41 is set at the retraction position, and the rollers 421 of the pair of Y-axis roller mechanisms 42 are driven to rotate in the same direction, a conveying force in the Y-axis direction can be applied to the base material J from both sides of the placement plate 34.

[0067] In this way, the X-axis roller mechanisms 41 and the Y-axis roller mechanisms 42 do not operate simultaneously, but separately perform conveying in the X-axis direction and conveying in the Y-axis direction.

[0068] In addition, when the rollers 411 of the pair of X-axis roller mechanisms 41 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 applied to the base material J on the placement plate 34 such that slack can be suppressed.

[0069] In addition, when the rollers 421 of the pair of Y-axis roller mechanisms 42 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 applied to the base material J on the placement plate 34 such that slack can be suppressed.

[0070] Hereinafter, the operation control of applying tension to the base material J in each direction by the pair of X-axis roller mechanisms 41 or the pair of Y-axis roller mechanisms 42 is referred to as tension applying control.

[0071] During the hair planting operation of binding the hair for planting M to the base material J, the moving mechanism 25 described above is used for moving the base material J together with the placement plate 34, and positioning each mesh hole of the base material J in the range of the work opening 341 with respect to the hook needles of the first to third capture mechanisms 21 to 23.

[0072] In contrast, the feed device 40 is used for moving the base material J with respect to the placement plate 34 and shifting the range of the base material J facing the work opening 341 of the placement plate 34 to another position in the base material J.

[0073] Therefore, the movement of the base material J by the moving mechanism 25 is finely controlled by a very small amount of movement compared with the movement of the base material J by the feed device 40.

[0074] Note that, while the configuration in which the roller mechanisms 41 and 42 in two intersecting directions respectively perform the feed in the X-axis direction and the Y-axis direction orthogonal to each other is shown herein, aspects are not limited thereto, and a configuration in which the feed is performed in two obliquely intersecting directions is also possible.

[0075] Note that the base stage 30 includes a cover member 35 that covers the base stage 30 and the feed device 40. The cover member 35 has a substantially convex polyhedron shape with an upper end portion thereof protruding upward, and a center of the upper end portion is widely cut out such that the upper portions of the rollers 411 and 421 and the placement plate 34 are respectively exposed upward. The upper end portion of the base stage 30 may have a polyhedral shape closer to a spherical shell or may have a substantially spherical shell shape.

[0076] With the cover member 35, the base material J placed on the placement plate 34 is prevented from direct contact with the configurations other than the respective rollers 411 and 421 of the feed device 40, with the corners of the base plate 32, or the like, allowing a smooth feed operation of the base material J by the feed device 40.

[0077] Note that the cover member 35 is omitted in the drawings other than FIG. 1.

[Clamp Device]

[0078] As shown in FIGS. 1 and 3 to 5, the clamp device 50 includes a clamp plate (clamp member) 51 including a flat plate body elongated in the Y-axis direction above the base stage 30, a pair of support bases 52 erected on the upper surface of the stage plate 271 of the Y-axis stage 27 to individually support both end portions of the clamp plate 51, a slide guide 53 that allows lifting and lowering of the clamp plate 51 with respect to each support base 52, a clamp air cylinder 54 serving as a lifting/lowering unit that lifts and lowers the clamp plate 51, and a coil spring 55 provided between each support base 52 and the clamp plate 51 and serving as an elastic member to press the clamp plate 51 upward.

[0079] Since the clamp device 50 is supported on the stage plate 271 of the Y-axis stage 27, the clamp device 50 is moved in the X-Y directions together with the base stage 30 by the moving mechanism 25.

[0080] At a position directly above the work opening 341 of the placement plate 34, the clamp plate 51 is formed with an upper opening 511 penetrating vertically therethrough and having substantially the same shape and size as those of the work opening 341.

[0081] A lower surface of the clamp plate 51 can be brought into contact with the placement surface of the placement plate 34 at a lower limit position of the lifting and lowering operation. The clamp plate 51 can clamp the base material J placed on the placement plate 34 from above to fixedly hold the base material J by being lowered to the lower limit position.

[0082] Furthermore, at the lower limit position of the lifting and lowering operation, the work opening 341 of the mounting plate 34 and the upper opening 511 can be overlapped at substantially the same position in a plan view.

[0083] The second and third capture mechanisms 22 and 23 described above are arranged above the clamp plate 51, and extend the hook needles downward to perform a binding operation of the hair for planting M within a range of the base material J in the work opening 341 through the upper opening 511.

[0084] In addition, four contact plates 512 that individually come into contact with outer circumferences of the respective rollers 411 and 421 are provided on four sides of the upper opening 511 on the lower surface side of the clamp plate 51. Each contact plate 512 has a lower surface positioned lower than the lower surface of the clamp plate 51, and comes into contact with an upper portion of each of the rollers 411 and 421 at a position immediately before the clamp plate 51 lowers to the lower limit position of the lifting and lowering operation. In this way, by lowering the clamp plate 51 to a position immediately before the lower limit position, the base material J on the placement plate 34 can be properly brought into contact with each of the rollers 411 and 421, and the feed operation by the pair of X-axis roller mechanisms 41 or the pair of Y-axis roller mechanisms 42 can be performed properly.

[0085] FIGS. 8 to 10 are front views of the clamp device 50 with the clamp plate 51 at different heights, respectively.

[0086] FIG. 8 shows a state in which the clamp plate 51 is positioned at a lifted position, which is an upper limit of the lifting and lowering operation, by lifting pressure of each clamp air cylinder 54. In this state, the lower surface of the clamp plate 51 is significantly spaced apart from the placement surface of the placement plate 34.

[0087] At the lifted position, the base material J on the placement plate 34 is in an unclamped state. Since the clamp plate 51 at the lifted position is significantly spaced apart from the placement plate 34, the hair for planting M can be swept out through a wiper member 611 of the wiper mechanism 61 described below.

[0088] Each clamp air cylinder 54 is provided with a regulator 56 in a supply path from a pneumatic source, and air pressure for lowering the clamp plate 51 can be applied to each clamp air cylinder 54 in two stages of high and low pressures, under control of the control device 100.

[0089] FIG. 9 shows a state of the clamp plate 51 when the lowering pressure of each clamp air cylinder 54 is at a low pressure, and FIG. 10 shows a state of the clamp plate 51 when the lowering pressure of each clamp air cylinder 54 is at a high pressure.

[0090] As shown in FIG. 9, when the lowering pressure of each clamp air cylinder 54 is at a low pressure, the lowered clamp plate 51 cannot withstand the upward pressing force received from the coil spring 55, so that a gap d is formed between the lower surface of the clamp plate 51 and the placement surface of the placement plate 34, and the base material J is brought into a state of being restrained by a small clamping force of the clamp or not restrained. The height of the clamp plate 51 at this time is referred to as a weak clamp position.

[0091] On the other hand, at this weak clamp position, each contact plate 512 of the clamp plate 51 contacts each of the rollers 411 and 421 or forms a very narrow gap with respect to each of the rollers 411 and 421. Therefore, when the base material J is placed on the placement plate 34, the base material J is pushed by each contact plate 512 into contact with each of the rollers 411 and 421 with an appropriate contact force such that the feed operation by the pair of X-axis roller mechanisms 41 or the pair of Y-axis roller mechanisms 42 can be performed properly.

[0092] In contrast, as shown in FIG. 10, when the lowering pressure of each clamp air cylinder 54 is at a high pressure, the lowered clamp plate 51 can allow the lower surface of the clamp plate 51 and the placement surface of the placement plate 34 to be brought into a state of pressed contact, against the coil spring 55. Therefore, when the base material J is placed on the placement plate 34, the base material J is firmly gripped by the clamp plate 51 and the placement plate 34 and fixedly held with a large restraining force. The height of the clamp plate 51 at this time is referred to as a strong clamp position.

[0093] Additionally, a lighting device 57 is provided on the upper surface of the clamp plate 51. The lighting device 57 irradiates illumination light from above the upper opening 511 when the camera 11 described below captures an image of the base material J through the work opening 341 from below the placement plate 34. The lighting device 57 is retracted to one end portion side of the clamp plate 51 during non-imaging, and is moved directly above the upper opening 511 by an actuator (not shown) to project light downward during imaging.

[Hair Supply Device]

[0094] FIG. 11 is a perspective view of the hair supply device 74 and the hair holding mechanism 68, and FIG. 12 is a right side view.

[0095] The hair supply device 74 is installed on the base 12 at a position on a front left side of the base stage 30.

[0096] The hair supply device 74 allows a spatula member to be inserted near an upper end portion of a bundle Mb of numerous hairs for planting M held upright along the vertical direction so as to separate several hairs for planting M, and further to be rotated so that the upper end portions of the separated hairs for planting M are tilted to face rearward.

[0097] In addition, the hair supply device 74 includes a head 741 that suctions and internally grips a tip portion of one of the plurality of tilted hairs M for planting, and conveys the head 741 rearward in the X-axis direction so that one hair for planting M can be pulled out straight rearward. In FIG. 11, reference sign Mp denotes a pull-out position of the hair for planting M targeted by the head 741 of the hair supply device 74.

[0098] Note that the hair supply device 74 includes a gripping mechanism (not shown) that grips a front end portion side of the hair for planting M pulled out by the head 741 to the pull-out position Mp.

[Hair Holding Mechanism]

[0099] FIG. 13 is a perspective view of the hair holding mechanism 68, FIG. 14 is a plan view, and FIGS. 15 and 16 are explanatory diagrams of an operation in a plan view.

[0100] As shown in FIGS. 11 to 16, the hair holding mechanism 68 is installed on the base 12 at a position located rearward of the hair supply device 74 and to the left of the base stage 30.

[0101] The hair holding mechanism 68 includes a first gripping mechanism 69 and a second gripping mechanism 70 that grip both end portions of the hair for planting M, respectively, a conveying mechanism 71 that supports and conveys the gripping mechanisms along the Y-axis, and a recovery device 75 that recovers the hair for planting M that remains in the first gripping mechanism 69 due to an error or the like.

[0102] The conveying mechanism 71 includes a movable body 711 having a flat plate shape along the X-Y plane, a support body 712 having an elongated flat plate shape and erected at a right end portion of the movable body 711, a pair of slide rails 713 provided at front and rear end portions of the movable body 711 along the Y-axis direction, a slide base 714 that slidably supports each slide rail 713 along the Y-axis direction, an endless annular feed belt 715 extending between two sprockets along the Y-axis direction, and a feed motor 716 serving as an actuator that conveys the feed belt 715.

[0103] The support body 712 supports the first gripping mechanism 69 and the second gripping mechanism 70 arranged in the front-rear direction in the right plane.

[0104] The movable body 711 that holds the support body 712 includes two slide bases 714 provided for each slide rail 713, and each of the slide bases 714 is fixedly supported by a support plate (not shown) provided on the upper side of the movable body 711. In addition, the movable body 711 is connected to the feed belt 715 and is conveyed by driving of the feed motor 716 by a desired amount of operation.

[0105] Accordingly, the conveying mechanism 71 can arbitrarily move and position the first gripping mechanism 69 and the second gripping mechanism 70 along the Y-axis direction.

[0106] The first gripping mechanism 69 includes a structure similar to a thread tensioner device mounted on a sewing machine. That is, this first gripping mechanism 69 includes a bracket 691 supported by the support body 712, two disk-shaped sliding plates 692 and 693 that slidably grip hair for planting M, a coil spring 694 serving as an elastic body that applies gripping pressure to the two sliding plates 692 and 693, a support shaft 695 that supports the sliding plates 692 and 693 and the coil spring 694, an adjustment body 696 that adjusts gripping pressure, and a release mechanism 72 that switches the first gripping mechanism 69 from a gripped state to a released state.

[0107] The bracket 691 is a substantially L-shaped member when viewed from the front, having a vertical plate portion that is fixedly connected to a front side of a right surface of the support body 712 by a bolt or the like, and an extension extending rightward from a lower end portion of the vertical plate portion.

[0108] The extension of the bracket 691 has a flat plate shape along the X-Y plane, and at its right end portion, the support shaft 695 is erected along the Z-axis direction.

[0109] The two sliding plates 692 and 693 each have a through hole formed in a center thereof, and the support shaft 695 is inserted into the through holes. The two sliding plates 692 and 693 are supported movably along the support shaft 695 in a vertically overlapping state.

[0110] In addition, both the sliding plates 692 and 693 have outer edge portions that are slightly bent backward over their entire circumferences so as to be separated from each other, thereby forming a gap.

[0111] The support shaft 695 is erected along the Z-axis direction and supports the coil spring 694, the sliding plate 692, and the sliding plate 693 arranged in order from above.

[0112] The two sliding plates 692 and 693 are held by spring pressure of the coil spring 694 in a state in which the peripheries of their central portions are in pressure contact with each other.

[0113] A male thread is formed on an outer circumference of an upper end portion of the support shaft 695. The adjustment body 696 has a nut shape and is screwed onto the male thread of the upper end portion of the support shaft 695.

[0114] By screwing the adjustment body 696 onto the support shaft 695 and rotating it, an amount of extension and contraction of the coil spring 694 can be changed, and the gripping pressure of the two sliding plates 692 and 693 can be thus adjusted.

[0115] The two sliding plates 692 and 693 are intended to hold the hair for planting M by sandwiching it therebetween, and the gripping pressure of the two sliding plates 692 and 693 is preferably adjusted to such an extent that, when the hair for planting M is pulled with a tension within a range that does not cause it to stretch or break, it slides and can be pulled out.

[0116] In addition, the two sliding plates 692 and 693 are preferably formed of metal plates or resin plates having sliding properties so as to cause the hair for planting M to slide.

[0117] In addition, since the outer circumferences of the two sliding plates 692 and 693 are bent backward, the hair for planting M can be easily pushed between the sliding plates from the outer circumference sides thereof.

[0118] The head 741 of the hair supply device 74 described above can pull out one hair for planting M to a pull-out position Mp located rearward of the first gripping mechanism 69 and the second gripping mechanism 70. The pull-out position Mp is to the right of a retraction position at which the first gripping mechanism 69 and the second gripping mechanism 70 are positioned at the leftmost side by the conveying mechanism 71. In addition, a height of the hair for planting M that is pulled out by the head 741 of the hair supply device 74 matches a height between the two sliding plates 692 and 693.

[0119] Therefore, when the first gripping mechanism 69 is conveyed rightward from the retraction position by the conveying mechanism 71, the hair for planting M can be received and gripped between the two sliding plates 692 and 693.

[0120] The release mechanism 72 includes an insertion plate 73 that can be inserted between two sliding plates 692 and 693 of the first gripping mechanism 69, a support member 721 that supports the insertion plate 73, a slide shaft 722 extending leftward from the support member 721, a sleeve 723 that is provided on the movable body 711 and slidably supports the slide shaft 722 along the Y-axis direction, and a release air cylinder 724 that imparts a reciprocating motion to the insertion plate 73 along the Y-axis direction via the support member 721.

[0121] The insertion plate 73 is arranged on the left side of the first gripping mechanism 69 while being placed on an upper surface of the extension of the bracket 691.

[0122] The insert plate 73 has a rectangular flat plate shape along the X-Y plane, and a cutout portion 731 is formed that is largely cut out in a substantially U-shape from a right end portion thereof toward the left. In addition, an insert portion 732 is formed along a cut-out inner edge portion of the U-shaped cutout portion 731. The insertion portion 732 is formed in a plate shape with a smaller thickness in the Z-axis direction compared to other portions of the insertion plate 73.

[0123] Furthermore, the insertion portion 732 has an inclined surface 732a formed so that a right end portion thereof becomes thinner toward the right. A height of a tip portion of the inclined surface 732a of the insertion portion 732 is set to match the height between the two sliding plates 692 and 693 by a portion of the insertion plate 73 other than the insertion portion 732.

[0124] Therefore, as shown in FIGS. 15 and 16, when the insertion plate 73 moves rightward over the upper surface of the extension of the bracket 691, the tip portion of the inclined surface 732a of the insertion portion 732 easily enters between the two sliding plates 692 and 693, and the entire insertion portion 732 is inserted, thereby separating the two sliding plates 692 and 693 against the spring pressure of the coil spring 694 to form a gap.

[0125] As a result, the hair for planting M gripped by the two sliding plates 692 and 693 can be released from the gripped state.

[0126] In addition, the insertion portion 732 of the insertion plate 73 is formed from the right end portion of the insertion plate 73 toward the left over substantially the same range as a diameter of each of the sliding plates 692 and 693. For this reason, as shown in FIG. 16, when the insertion plate 73 is moved rightward to the maximum extent, the tip portion of the insertion plate 73 can feed out the hair for planting M rightward from the entire range between the two sliding plates 692 and 693 and discharge it. In this case, the substantially U-shaped cutout portion 731 is cut out to such an extent that it does not interfere with the support shaft 695 of the first gripping mechanism 69.

[0127] The release air cylinder 724 is fixedly mounted on an upper surface of the movable body 711 with its plunger oriented rightward, and a tip portion of the plunger penetrates the support member 721 and the bracket 691 of the first gripping mechanism 69 and is fixedly connected to a left surface of the support member 721.

[0128] Since the support member 721 is also connected to the slide shaft 722 at an upper end portion of its left surface, it is in a state of being supported by two shafts, and the support member 721 and the insertion plate 73 can reciprocate along the Y-axis direction while maintaining a stabilized posture.

[0129] As shown in FIG. 13, the second gripping mechanism 70 includes a frame body 701 fixedly supported on the support body 712, two gripping members 702 and 703 for gripping the hair for planting M, and gripping air cylinders 704 and 705 serving as lifting and lowering actuators for individually lifting and lowering the respective gripping members 702 and 703.

[0130] The frame body 701 is rectangular in shape when viewed from a side, and the gripping air cylinders 704 and 705 are placed on its upper surface.

[0131] Both the two gripping members 702 and 703 have flat extensions extending rightward. The gripping members 702 and 703 are supported by the frame body 701 such that a lower surface of the extension of the gripping member 702 and an upper surface of the extension of the gripping member 703 are aligned vertically to face each other.

[0132] The upper gripping member 702 is supported so as to be switchable in position between upper and lower positions by the gripping air cylinder 704.

[0133] Similarly, the lower gripping member 703 is supported so as to be switchable in position between upper and lower positions by the gripping air cylinder 705.

[0134] When the upper gripping member 702 is at the lower position and the lower gripping member 703 is at the upper position by the gripping air cylinders 704 and 705, the lower surface of the extension of the upper gripping member 702 and the upper surface of the extension of the lower gripping member 703 are brought into pressure contact, and the hair for planting M can be gripped from above and below more strongly than by the first gripping mechanism 69.

[0135] Note that the lower surface of the extension of the upper gripping member 702 and the upper surface of the extension of the lower gripping member 703 are both subjected to anti-slip treatment, so that, unlike in the case of the first gripping mechanism 69, the hair for planting M gripped by the second gripping mechanism 70 is less likely to be pulled out.

[0136] As shown in FIG. 14, the first gripping mechanism 69 and the second gripping mechanism 70 can be arbitrarily positioned along the Y-axis direction by the conveying mechanism 71.

[0137] The first gripping mechanism 69 and the second gripping mechanism 70 are set to a position indicated by a solid line in FIG. 14 as a retraction position P0, which is a limit position of leftward movement. The first gripping mechanism 69 and the second gripping mechanism 70 are placed in standby at the retraction position P0 at the start of a knotting operation (binding operation) of the hair for planting M to the base material J, and also return to the retraction position P0 after completion of the operation.

[0138] In addition, the first gripping mechanism 69 and the second gripping mechanism 70 are set to a position indicated by a chain double-dashed line slightly to the right of the retraction position P0, as a receiving position P1 for receiving the hair for planting M that has been pulled out to the pull-out position Mp by the hair supply device 74 described above. At the receiving position P1, as the first gripping mechanism 69 moves rightward, the hair for planting M is automatically inserted between the two sliding plates 692 and 693 and brought into a gripped state. In addition, the second gripping mechanism 70 moves the upper gripping member 702 from the upper position to the lower position and the lower gripping member 703 from the lower position to the upper position by the gripping air cylinders 704 and 705, so that the hair for planting M is brought into a gripped state.

[0139] The hair for planting M is held between the first gripping mechanism 69 and the second gripping mechanism 70 while being aligned with the Y-axis.

[0140] In addition, the first gripping mechanism 69 and the second gripping mechanism 70 are set to a position indicated by a chain double-dashed line and located rightward from the receiving position P1, as a supply position P2.

[0141] The supply position P2 is a position where the hair for planting M gripped by the first gripping mechanism 69 and the second gripping mechanism 70 is superimposed on a center position of the upper opening 511 of the clamp plate 51 in a plan view. At the supply location P2, the knotting operation (binding operation) of the hair for planting M to the base material J is performed.

[0142] In addition, the first gripping mechanism 69 and the second gripping mechanism 70 are set to a position between the receiving position P1 and the supply position P2 in the Y-axis direction, as a recovery position P3.

[0143] The recovery position P3 is a position where the hair for planting M, which remains gripped by the first gripping mechanism 69 due to a capture error or unintentional cutting of the hair for planting M during the knotting operation of the hair for planting M, is recovered.

[0144] The recovery device 75 for the hair for planting M is arranged in the vicinity of the front side of the first gripping mechanism 69 at the recovery position P3.

[0145] At the recovery position P3, the first gripping mechanism 69 operates the release mechanism 72 to open the two sliding plates 692 and 693 into a released state, and if any hair for planting M remains, discharges it to the outside by the insertion plate 73.

[0146] The recovery device 75 includes a suction nozzle 751 expanded rearward, an intake blower 752 (see FIG. 2) in communication with the suction nozzle 751, and a trap (not shown) formed of a mesh or the like for repair of the hair for planting M and provided between the suction nozzle 751 and the intake blower 752.

[0147] The recovery device 75 drives the intake blower 752 when the release mechanism 72 is in operation, thereby suctioning and recovering the hair for planting M, if any, discharged from the first gripping mechanism 69.

[0148] Note that since the second gripping mechanism 70 performs a release operation from the gripped state at the supply position P2, when an unexpected cutting of the hair for planting M occurs, a cut end portion of the hair for planting M on the second gripping mechanism 70 side is released at the supply position P2. Therefore, considering such a case, the recovery device 75 may also be arranged near the second gripping mechanism 70 at the supply location P2.

[Hair Planting Unit]

[0149] The first to third capture mechanisms 21 to 23 and the looper mechanism 24 constitute the hair planting unit 20 that knots and binds the hair for planting M to the base material J.

[0150] The first to third capture mechanisms 21 to 23 respectively include hook needles 211 to 231 each having a barb provided near a tip, ball screw mechanisms (not shown) for moving the hook needles forward and backward, and capture motors (not shown) serving as drive sources for lifting and lowering operations of the hook needles 211 to 231.

[0151] The first capture mechanism 21 is arranged below the work opening 341 of the placement plate 34, with the hook needle 211 oriented vertically upward. The placement plate 34 can move in the X-Y direction by the moving mechanism 25. The first capture mechanism 21 is arranged on the base 12 so that a center position of the work opening 341 and the hook needle 211 are aligned in a plan view, with the placement plate 34 positioned at a preset reference position by the moving mechanism 25.

[0152] The second capture mechanism 22 is arranged above the upper opening 511 of the clamp plate 51, with the hook needle 221 oriented vertically downward.

[0153] The hook needle 221 of the second capture mechanism 22 is arranged above the base 12 so as to be slightly to the left of the hook needle 211 of the first capture mechanism 21 in a plan view. Note that, strictly, the second capture mechanism 22 is supported on a support plate (not shown) erected on the base 12.

[0154] The second capture mechanism 22 also includes an actuator that turns the hook needle 221. The first and third capture mechanisms 21 and 23 may also include actuators that turn the hook needles 211 and 231, respectively.

[0155] The third capture mechanism 23 is arranged above the upper opening 511 of the clamp plate 51 and behind the second capture mechanism 22, with the hook needle 231 oriented obliquely forward and downward.

[0156] The hook needle 231 of the third capture mechanism 23 is arranged above the base 12 so that its center line intersects a center line of the hook needle 221 of the second capture mechanism 22 at a position slightly above the placement surface of the placement plate 34. Note that, strictly, the third capture mechanism 23 is also supported on the support plate (not shown) erected on the base 12.

[0157] The looper mechanism 24 is arranged above the first capture mechanism 21 and below the lower surface of the placement plate 34.

[0158] The looper mechanism 24 includes a pair of arm portions 241 extended to the right to widen a loop of the hair for planting M pulled into the lower side of the base material J by the first capture mechanism 21. Additionally, the looper mechanism 24 includes an actuator that separates tip portions of the pair of arm portions 241 in the X-axis direction, and an actuator that moves the pair of arm portions 241 along the Y-axis direction.

[0159] The configuration of the hair planting unit 20 and the binding operation of the hair for planting M to the base material J are substantially the same as those disclosed in JP2018-040084A. Therefore, reference is made to the above publication for the details of the configuration of the hair planting unit 20 and the binding operation of the hair for planting M to the base material J, and only a brief description will be provided herein.

[0160] FIGS. 17A to 19B are explanatory diagrams of the binding operation of the hair for planting M. FIGS. 17A, 18A, and 19A show the periphery of the looper mechanism 24 in a right side view, and FIGS. 17B, 18B, and 19B show the periphery in a rear view.

[0161] In addition, in each drawing, the first gripping mechanism 69 and the second gripping mechanism 70 described above are schematically shown, but for the sake of explanation, they are shown smaller in size than in reality and closer to the looper mechanism 24 than in reality. In the binding operation of the hair for planting M, as shown in FIGS. 17A and 17B,

[0162] the hair for planting M is supported along the front-rear direction by the first gripping mechanism 69 and the second gripping mechanism 70 on the upper side of the base material J held on the upper surface of the placement plate 34.

[0163] In this state, the hook needle 211 of the first capture mechanism 21 advances and retracts from below through the mesh hole H1 of the base material J, captures the hair for planting M, and pulls it into the mesh hole H1 to form a loop.

[0164] Furthermore, the pair of arm portions 241 of the looper mechanism 24 is allowed to enter the loop of the hair for planting M by rightward movement, and moves leftward while opening to pull the loop to the lower side of the adjacent mesh hole H2 on the left.

[0165] Then, the hook needle 221 of the second capture mechanism 22 advances and retracts from above through the mesh hole H2 of the base material J, captures the loop of the hair for planting M, and pulls it into the mesh hole H2 to form a small loop on the upper side of the base material J.

[0166] Then, as shown in FIGS. 18A and 18B, the hook needle 221 of the second capture mechanism 22 turns to apply a twist to the small loop, and the hook needle 231 of the third capture mechanism 23 advances from an obliquely rearward and upward direction, enters the small loop, and captures an end portion of the hair for planting M on the first gripping mechanism 69 side.

[0167] Then, as shown in FIGS. 19A and 19B, the hook needle 231 of the third capture mechanism 23 retracts to insert the entire end portion on the first gripping mechanism 69 side into the small loop of the hair for planting M, the hook needle 221 of the second capture mechanism 22 comes out of the small loop, and the looper mechanism 24 moves the pair of arm portions 241 leftward to release the hair for planting M.

[0168] A terminal end of the hair for planting M is pulled out from the first gripping mechanism 69 while sliding, and passes through the small loop. Furthermore, the hair for planting Mis tensioned by the hook needle 231 until it is knotted to a boundary portion between the mesh hole H1 and the mesh hole H2, and the second gripping mechanism 70 releases the hair for planting M, whereby the binding operation of the hair for planting M is completed.

[0169] Note that the hook needle 231 of the third capture mechanism 23 may be provided with a gripping mechanism for holding the captured state of the hair for planting M.

[Auxiliary Clamp Mechanism]

[0170] As shown in FIG. 3, the auxiliary clamp mechanisms 62 are provided on both sides of the base stage 30 in the X-axis direction, respectively. The two auxiliary clamp mechanisms 62 are arranged to individually face the two X-axis roller mechanisms 41.

[0171] Each of the auxiliary clamp mechanisms 62 includes an auxiliary clamp plate 621 provided to be tiltable, and an auxiliary clamp air cylinder 622 for tilting the auxiliary clamp plate 621.

[0172] The auxiliary clamp plate 621 is formed as a flat plate having a base end portion tiltably supported about the Y-axis and a tip portion in contact with the outer circumferential surface of the roller 411 of the X-axis roller mechanism 41.

[0173] The auxiliary clamp air cylinder 622 applies tilting force in a direction in which the tip portion of the auxiliary clamp plate 621 comes into contact with the outer circumferential surface of the roller 411. As a result, the base material J placed on the placement plate 34 is sandwiched and held between the X-axis roller mechanism 41 and the tip portion of the auxiliary clamp plate 621.

[0174] For example, the two auxiliary clamp mechanisms 62 are provided to press the base material J so as to prevent misalignment of the base material J with respect to the placement plate 34, when the clamp plate 51 of the clamp device 50 is set to the lifted position and the base material J on the placement plate 34 is released.

[0175] When the base material J is clamped by the two auxiliary clamp mechanisms 62, the base material J is likely to become slack due to the pressing by the tip portion of the auxiliary clamp plate 621. Therefore, it is preferable to simultaneously perform the tension applying control by the pair of X-axis roller mechanisms 41 described above.

[Wiper Mechanism]

[0176] As shown in FIGS. 3 and 4, the wiper mechanism 61 is a mechanism for sweeping the hair for planting M bound to the base material J.

[0177] As described above, the operation of planting hair to the base material J is performed through the work opening 341 and the upper opening 511 while the base material J is held by the clamp plate 51.

[0178] In this case, each hair for planting M bound to the base material J protrudes upward of the clamp plate 51 through the upper opening 511.

[0179] On the other hand, when the planting of the hair for planting M is completed in one section in the work opening 341 of the placement plate 34 in the base material J, the clamp plate 51 is lifted to the weak clamp position, and the feed device 40 performs the feed operation of the base material J such that an adjacent section is within the work opening 341.

[0180] Then, if each hair for planting M that has been planted remains inserted in the upper opening 511, it may possibly affect the feed operation of the base material J, the binding operation of the hair for planting M in the next section, the image capturing of a new section through the work opening 341, and the like.

[0181] Therefore, the clamp plate 51 is lifted to the lifted position, and the operation of sweeping, with the wiper mechanism 61, the hair for planting M bound to the base material J below the clamp plate 51 and sweeping out each hair for planting M from the upper opening 511 is performed.

[0182] Note that the operation of feeding the base material J and the operation of sweeping out the hair for planting M may be performed in reverse order.

[0183] As shown in FIG. 3, the wiper mechanism 61 is arranged on a rear right side of the mounting plate 34 in a plan view. In addition, the wiper mechanism 61 is arranged lower than the clamp plate 51 at the lifted position and higher than the placement plate 34.

[0184] The wiper mechanism 61 includes a rod-shaped wiper member 611 that sweeps each hair for planting M, a telescopic air cylinder 612 that extends and contracts the wiper member 611, and a sweeping-out air cylinder 613 that moves the wiper member 611 forward and rearward for sweeping-out.

[0185] The wiper member 611 has a round rod shape along the Y-axis direction and extends leftward from the telescopic air cylinder 612.

[0186] The telescopic air cylinder 612 is supported by the sweeping-out air cylinder 613 so that a plunger moving forward and rearward is parallel to the Y-axis direction. The plunger of the telescopic air cylinder 612 is directly connected to the wiper member 611 in the extending direction thereof and can switch between a state in which the wiper member 611 is contracted rightward and a state in which the wiper member 611 is extended leftward.

[0187] In the contracted state, the wiper member 611 is positioned to the right of the placement plate 34, and in the extended state, the wiper member 611 overlaps the placement plate 34 in the Y-axis direction.

[0188] The sweeping-out air cylinder 613 is supported by the base 12 so that the plunger is parallel to the X-axis direction. The telescopic air cylinder 612 can be supported at the tip portion of the plunger, and the wiper member 611 can be moved forward of the placement plate 34 when the plunger is advanced, and rearward of the placement plate 34 when the plunger is retracted.

[0189] With the above configuration, when binding the hair for planting M to one section in the work opening 341 of the placement plate 34 is completed and the clamp plate 51 is lifted to the lifted position, the wiper mechanism 61 advances the wiper member 611 by the sweeping-out air cylinder 613, extends the wiper member 611 by the telescopic air cylinder 612, and then retracts the wiper member 611 by the sweeping-out air cylinder 613.

[0190] As a result, the wiper member 611 can pass between the work opening 341 of the placement plate 34 and the upper opening 511 of the clamp plate 51, sweep each hair for planting M rearward, and sweep it out through the upper opening 511.

[0191] Note that the wiper member 611 may take any form as long as it can sweep the hair for planting M. For example, the wiper member 611 is not limited to a round rod shape and may take the shape of a plate or a brush.

[First Blower Mechanism]

[0192] The first blower mechanism 64 has a nozzle connected to a pneumatic supply source. As shown in FIGS. 3 and 4, the first blower mechanism 64 is arranged forward of and slightly above the placement plate 34, and below the clamp plate 51 at the lifted position, and blows air obliquely rearward and downward toward the placement plate 34 side.

[0193] As described above, the hair for planting M collectively swept rearward by the wiper mechanism 61 tends to rise upward of the base material J from the state of being swept rearward due to the elasticity thereof. In this case, when clamping the base material J to a new section by the clamp device 50, there is a risk that the hair for planting M will be caught between the placement plate 34 and the clamp plate 51.

[0194] For this reason, the first blower mechanism 64 blows air to the hair for planting M swept rearward by the wiper mechanism 61 so that the hair does not rise.

[Second Blower Mechanism]

[0195] The second blower mechanism 65 has a nozzle connected to a pneumatic supply source. As shown in FIG. 1, the second blower mechanism 65 is provided at each of both end portions of the clamp plate 51 in the Y-axis direction, and each of the second blower mechanisms 65 blows air toward the placement plate 34 side, on the lower side of the clamp plate 51.

[0196] These second blower mechanisms 65 have a function of blowing air to press the base material J against the cover member 35 and the respective rollers 411 and 421 when the clamp plate 51 is lifted to release the base material J on the placement plate 34.

[0197] In addition, the second blower mechanisms 65 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 M toward the downstream side in the feed direction of the base material J when the feed device feeds the base material J such that the adjacent section in the Y-axis direction is within the work opening 341, and the wiper mechanism 61 performs the sweeping operation.

[Camera]

[0198] As shown in FIG. 1, the camera 11 captures an image of the base material J from below the placement plate 34 through the work opening 341. The camera 11 includes an image sensor such as a charge-coupled device (CCD) or a complementary metal oxide semiconductor (CMOS) and an optical system.

[0199] The camera 11 is supported by the position switch mechanism 28 (see FIG. 2) together with the first capture mechanism 21. The camera 11 and the first capture mechanism 21 can be switched in position by a position switch air cylinder 283 of the position switch mechanism 28 between a state in which an optical axis of the camera 11 is aligned with the center line along the Z-axis direction passing through the center of the work opening 341 and a state in which the center line of the hook needle held by the first capture mechanism 21 is aligned with the center line.

[0200] Note that the position switch mechanism 28 is installed directly on the base 12 and does not cause movement on the base 12. In contrast, the placement plate 34 is installed on the base 12 via the moving mechanism 25. Therefore, in a plan view, the placement plate 34 is relatively movable in the X-axis direction and the Y-axis direction with respect to the position switch mechanism 28. For this reason, the center of the work opening 341 refers to the center of the work opening 341 in a state in which the placement plate 34 is positioned at the center of the movable range by the moving mechanism 25 (as the reference position of the placement plate 34).

[Correction Mechanism]

[0201] The base material J is a mesh material with mesh holes aligned and developed on its surface. For example, the base material J of the present embodiment has hexagonal mesh holes aligned. When performing the operation of sequentially binding the hair for planting M to each mesh hole of the base material J, the alignment direction of the mesh holes is held on the placement plate 34 so as to be parallel to the X-axis or Y-axis direction, which is the feed direction of the feed device 40.

[0202] However, the alignment direction of the mesh holes may be inclined due to a variety of factors, such as when displacement occurs due to sliding of the base material J during feeding, when the base material J is not planar but has a three-dimensional shape or is made of a soft material that is easily deformable, and the like.

[0203] The inclination of the mesh holes of the base material J can be detected from the image captured by the camera 11.

[0204] When the inclination of the mesh holes of the base material J exceeds an allowable value, the orientation of the base material J on the base stage 30 can be corrected by rotating the base material J about the Z-axis with respect to the camera 11 by the correction mechanism 63.

[0205] The correction mechanism 63 is arranged in front of the placement plate 34, as shown in FIGS. 3 to 5. The correction mechanism 63 includes a support shaft 632 rotatably supported around the Z-axis by a bracket 631 installed on the base 12, an arm 633 fixed to an upper end portion of the support shaft 632, a disc-shaped pressing plate 634 provided at a tip portion of the arm 633, a correction motor 635 (see FIG. 2) that rotates the pressing plate 634 via a belt mechanism, and an arm turning air cylinder 636 (see FIG. 2) that imparts rotational motion to the support shaft 632.

[0206] The support shaft 632 is supported along the Z-axis direction by the bracket 631.

[0207] The arm 633 is connected to the support shaft 632 via a spline nut 637. That is, the arm 633 can be moved along the support shaft 632 and rotated around the Z-axis together with the support shaft 632 by the spline nut 637.

[0208] In addition, the arm 633 is pressed upward by a coil spring 638, which is an elastic member, via the spline nut 637.

[0209] The pressing plate 634 provided on a lower surface side of the tip portion of the arm is rotatably supported around the Z-axis at the tip portion of the arm 633. The pressing plate 634 is imparted with rotational motion from the correction motor 635 by a belt mechanism provided on the upper surface side of the arm 633. In addition, the lower surface side of the pressing plate 634 contacts the base material J placed on the base stage 30 from above, so that the rotation of the pressing plate 634 can be imparted to the base material J.

[0210] In addition, the arm 633 is always pressed upward by the coil spring 638, thereby keeping the pressing plate 634 at a height away from the base material J on the base stage 30.

[0211] A pressing air cylinder 639 for lowering the arm 633 against the coil spring 638 is arranged in parallel with the arm 633, and when performing correction by rotation of the base material J, the pressing plate 634 can be lowered to contact the base material J on the placement plate 34.

[0212] In addition, the arm turning air cylinder 636 inputs rotational motion to the support shaft 632 via a link member (not shown) provided at a lower end portion of the support shaft 632.

[0213] By the rotational motion input from the arm turning air cylinder 636, the arm 633 can move the pressing plate 634 between a retraction position in front of the placement plate 34 and a pressing position directly above the placement plate 34.

[Control System of Hair Planting Apparatus: Control Device]

[0214] As shown in FIG. 2, the control device 100 of the hair planting apparatus 10 includes a read only memory (ROM) 102 that stores a program for controlling a hair planting operation, a random access memory (RAM) 103 serving as a work area for arithmetic processing, a non-volatile data memory 104 which serves as a 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) 101 that executes programs in the ROM 102.

[0215] In addition, the CPU 101 is connected to the first to third capture mechanisms 21 to 23, the looper mechanism 24, and the moving mechanism 25 that constitute the hair planting unit 20.

[0216] Each of the first to third capture mechanisms 21 to 23 includes a capture motor serving as a drive source for advancing and retracting operations of each of the hook needles 211 to 231, and the CPU 101 controls their operations through a drive circuit (not shown) that operates them.

[0217] The looper mechanism 24 includes a plurality of actuators, and the CPU 101 controls the operation of the looper mechanism 24 through a drive circuit (not shown) that operates the actuators.

[0218] The moving mechanism 25 includes the X-axis stage 26 and the Y-axis stage 27, and the CPU 101 controls the operations of the X-axis stage 26 and the Y-axis stage 27 through a drive circuit (not shown) that operates the X-axis motor 263 of the X-axis stage 26 and the Y-axis motor 273 of the Y-axis stage 27.

[0219] In addition, the CPU 101 is connected to the position switch mechanism 28 that switches the positions of the camera 11 and the first capture mechanism 21, and controls the position switch air cylinder 283 through an electromagnetic valve (not shown).

[0220] In addition, the CPU 101 is connected to the X-axis roller mechanism 41, controls the X-axis feed motor 412 through a drive circuit (not shown), and controls the retraction air cylinder 416 through an electromagnetic valve (not shown).

[0221] Similarly, the CPU 101 is connected to the Y-axis roller mechanism 42, controls the Y-axis feed motor 422 through a drive circuit (not shown), and controls the retraction air cylinder 426 through an electromagnetic valve (not shown).

[0222] Note that, although two X-axis roller mechanisms 41 and two Y-axis roller mechanisms 42 are provided, FIG. 2 shows only one of them, respectively.

[0223] In addition, the CPU 101 is connected to the clamp device 50, controls the clamp air cylinder 54 through an electromagnetic valve (not shown), and controls the strength of the air pressure supplied to the clamp air cylinder 54 by the regulator 56.

[0224] In addition, the CPU 101 is connected to the lighting device 57, switches ON/OFF of illumination light irradiation, and controls an actuator to move the lighting device 57 to a predetermined position.

[0225] In addition, the CPU 101 is connected to the wiper mechanism 61 and controls the telescopic air cylinder 612 and the sweeping-out air cylinder 613 through electromagnetic valves (not shown) connected to each thereof.

[0226] In addition, the CPU 101 is connected to the auxiliary clamp mechanism 62 and controls the auxiliary clamp air cylinder 622 through an electromagnetic valve (not shown).

[0227] Note that, although two auxiliary clamp mechanisms 62 are provided, only one is shown in FIG. 2.

[0228] In addition, the CPU 101 is connected to the correction mechanism 63, controls the correction motor 635 through a drive circuit (not shown), and controls the arm turning air cylinder 636 and the pressing air cylinder 639 through electromagnetic valves (not shown) connected to each thereof.

[0229] In addition, both the first blower mechanism 64 and the second blower mechanism 65 include electromagnetic valves for supplying high-pressure air to the nozzles, and the CPU 101 controls each electromagnetic valve to control discharge of the air.

[0230] In addition, the CPU 101 is connected to the hair holding mechanism 68, controls the conveying motor 716 through a drive circuit (not shown), controls the gripping air cylinders 704 and 705 and the release air cylinder 724 through electromagnetic valves (not show) connected to each thereof, and controls the intake blower 752 through a drive circuit (not shown).

[0231] In addition, the CPU 101 is connected to the camera 11 and controls the execution of image capturing of the base material J.

[0232] In addition, the CPU 101 is connected to a pedal 14 for inputting the start of the hair planting operation.

[0233] In addition, CPU 101 is connected to an operation panel 15 having a function as a display unit for displaying various information and a function as an input unit for performing various inputs.

[0234] Note that the CPU 101 controls various air cylinders, various motors, various actuators, and the like through 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.

[0235] In addition, a hair camera 76 shown in FIG. 2 is a necessary component in another embodiment described below, and is not an essential component in the hair planting apparatus of the present embodiment.

[Hair Planting Operation Control]

[0236] The overall flow of operation control of the hair planting operation executed by the CPU 101 is shown in a flow chart of FIG. 20.

[0237] First, as a preliminary preparation, the CPU 101 controls the clamp air cylinder 54 of the clamp device 50 to move the clamp plate 51 to the lifted position, and controls the auxiliary clamp air cylinders 622 of the respective auxiliary clamp mechanisms 62 to move the auxiliary clamp plates 621 to the released position spaced from the X-axis roller mechanism 41.

[0238] Then, the CPU 101 executes a step of base set (step S1).

[0239] That is, when the base material J is placed on the placement plate 34 of the base stage and the start of the hair planting operation is input from the pedal 14, the CPU 101 supplies low-pressure air to the clamp air cylinder 54 by the regulator 56 and lowers the clamp plate 51 to the weak clamp position.

[0240] Next, the CPU 101 executes a step of inclination detection (step S3).

[0241] That is, the CPU 101 controls the position switch air cylinder 283 of the position switch mechanism 28 to position the camera 11 such that the optical axis of the camera 11 coincides with the center of the work opening 341 at the reference position.

[0242] In addition, the CPU 101 controls the lighting device 57 to move above the upper opening 511 and to irradiate illumination light downward.

[0243] In addition, the camera 11 captures an image of the base material J within the range of the work opening 341, and the CPU 101 extracts a plurality of mesh holes developed on the surface of the base material J from the captured image, and detects a centroid point of each mesh hole.

[0244] Then, the CPU 101 detects the inclination of the base material J from the alignment direction of the plurality of centroid points, and determines whether the inclination exceeds an allowable value.

[0245] Next, the CPU 101 executes a step of correction control (step S5). The correction control is performed when it is determined in step S3 that the base material J is inclined. In addition, when it is determined that there is no inclination, this step is skipped.

[0246] As the correction control, the CPU 101 controls the correction mechanism 63, and rotates the base material J in a direction in which the detected inclination angle is corrected, by the correction motor 635 that holds the base material J from above with the pressing plate 634. Before and after the inclination correction, the slack of the base material J may be eliminated by the tension applying control by the feed device 40.

[0247] Then, the CPU 101 lowers the clamp plate 51 of the clamp device 50 to the weak clamp position and lifts each of the rollers 411 and 421 of the feed device 40 to the feed position.

[0248] Subsequently, the CPU 101 executes a step of hair planting operation (step S7).

[0249] In the step of hair planting operation, the CPU 101 captures an image of the base material J by the camera 11 to specify the binding location of the hair for planting M.

[0250] Then, the CPU 101 controls the position switch air cylinder 283 to arrange the first capture mechanism 21 at a reference position, and performs a supply operation of the hair for planting M.

[0251] Here, control of a supply operation of the hair for planting included in the step of hair planting operation will be described with reference to a flow chart of FIG. 21.

[0252] First, the CPU 101 controls the hair supply device 74 to cause the head 741 to grip one hair for planting M and pull out it to the pull-out position Mp (step S21).

[0253] Subsequently, the CPU 101 controls the feed motor 716 of the conveying mechanism 71 of the hair holding mechanism 68 to move the first and second gripping mechanisms 69 and 70 from the retraction position P0 to the receiving position P1 (step S23).

[0254] Since the hair for planting M is held under tension by the hair supply device 74, the first gripping mechanism 69, in the course of reaching the receiving position P1, grips the hair for planting M as it enters between the sliding plates 692 and 693.

[0255] On the other hand, in the second gripping mechanism 70, the gripping air cylinders 704 and 705 are controlled to switch the gripping member 702 to the lower position and the gripping member 703 to the upper position, so that the hair for planting M is gripped between the gripping members 702 and 703.

[0256] Subsequently, the CPU 101 controls the feed motor 716 to move the first and second gripping mechanisms 69 and 70 from the receiving position P1 to the supply position P2 (step S25).

[0257] Accordingly, the hair for planting M is arranged along the X-axis direction so as to pass over the center position of the work opening 341 in the vicinity of the upper surface of the base material J on the base plate 34 at the reference position.

[0258] Subsequently, the CPU 101 controls the hair planting unit 20 to perform a binding operation of the hair for planting M to the base material J (step S27). Since the binding operation has been described with reference to FIGS. 17A to 19B, the details thereof are omitted here.

[0259] Subsequently, the CPU 101 controls the feed motor 716 to move the first and second gripping mechanisms 69 and 70 from the supply position P2 to the recovery position P3 (step S29).

[0260] At the recovery position P3, the CPU 101 operates the release air cylinder 724 of the release mechanism 72, causing the insertion plate 73 to be inserted between the sliding plates 692 and 693 of the first gripping mechanism 69.

[0261] Accordingly, for example, when an error in the binding operation has occurred and the hair for planting M has remained in the first gripping mechanism 69, the hair for planting M is released from the gripped state and discharged from between the sliding plates 692 and 693 by the insertion plate 73.

[0262] In addition, the CPU 101 operates the intake blower 752 of the recovery device 75 together with the operation of the release mechanism 72, thereby suctioning and recovering the discharged hair for planting M, if any, from the suction nozzle 751.

[0263] Subsequently, the CPU 101 controls the feed motor 716 to move the first and second gripping mechanisms 69 and 70 from the recovery position P3 to the retraction position P0 (step S31).

[0264] In the step of hair planting operation (step S7), the CPU 101 sequentially positions each binding location within one section of the work opening 341 imaged by the camera 11 above the hook needle 211 of the first capture mechanism 21, and at each time, executes control of the supply operation of the hair for planting to perform the binding operation.

[0265] Then, if the binding of the hair for planting M has been completed for all binding locations in the section, the CPU 101 determines whether hair planting has been completed for all sections scheduled on the base material J (step S9). If hair planting has been completed for all sections, the CPU 101 lifts the clamp plate 51 of the clamp device 50 to the lifted position, releases the base material J on the placement plate 34, and terminates the hair planting operation.

[0266] On the other hand, if hair planting has not been completed for all sections, the CPU 101 executes a step of wiper operation (step S11).

[0267] That is, the CPU 101 lowers and retracts each of the rollers 411 and 421 of the feed device 40, clamps the base material J with each of the auxiliary clamp plates 621, and retracts the clamp plate 51 to the lifted position.

[0268] Then, the CPU 101 advances the wiper member 611 by the sweeping-out air cylinder 613 of the wiper mechanism 61, and extends the wiper member 611 by the telescopic air cylinder 612. Furthermore, by retracting the wiper member 611 with the sweeping-out air cylinder 613, the hair for planting M inserted in the upper opening 511 is swept rearward and swept out from the upper opening 511.

[0269] At this time, the first blower mechanism 64 blows air rearward to suppress the rising of the hair for planting M that has been swept rearward.

[0270] Then, the CPU 101 lowers the clamp plate 51 to the weak clamp position and releases the auxiliary clamping of the base material J made by each of the auxiliary clamp plates 621.

[0271] Subsequently, the CPU 101 executes a step of feed control (step S13).

[0272] That is, the CPU 101 feeds the base material J in predetermined section units by lifting each of the rollers 411 of the feed device 40 and driving the X-axis feed motor 412 to move the base material J in the X-axis direction, or by lifting each of the rollers 421 and driving the Y-axis feed motor 422 to move the base material J in the Y-axis direction.

[0273] After the feed operation to the next section is completed, the CPU 101 lowers the clamp plate 51 to the strong clamp position.

[0274] After that, the CPU 101 repeats steps S3 to S13 for all sections and then terminates the hair planting operation.

Technical Effects of Embodiment of Invention

[0275] As described above, the hair planting apparatus 10 includes: the release mechanism 72 that opens two sliding plates 692 and 693, which slidably grip the hair for planting M by the gripping pressure of the coil spring 694 in the first gripping mechanism 69 of the hair holding mechanism 68, thereby releasing the hair for planting M.

[0276] Therefore, in the case where the hair for planting M remains in the first gripping mechanism 69 due to an error in the binding operation of the hair for planting M, or the like, the hair for planting M can be easily discharged, and the gripping of the next hair for planting M in the first gripping mechanism 69 can be favorably performed. As a result, the hair planting operation can be stably performed.

[0277] In addition, since the release mechanism 72 includes the insertion plate 73 that is inserted between the two sliding plates 692 and 693 of the first gripping mechanism 69, the hair for planting M can be released simply by inserting the insertion plate 73 between the two sliding plates 692 and 693. As a result, the structure of the release mechanism 72 can be simplified and the stability of its operation can be improved.

[0278] In addition, since the insertion plate 73 of the release mechanism 72 has a function of discharging the hair for planting M present between the two sliding plates 692 and 693, the hair for planting M can be more accurately removed from the first holding mechanism 69.

[0279] In addition, the hair planting apparatus 10 includes the recovery device 75 that recovers the hair for planting M from between the two sliding plates 692 and 693.

[0280] Accordingly, the retention within the apparatus of the hair for planting M released from between the two sliding plates 692 and 693 can be suppressed, and cleanliness inside the apparatus and suppression of failures or malfunctions caused by residual hair for planting M can be achieved. 25

[Others]

[0281] Each embodiment of the present invention has been described. However, the present invention is not limited to the above embodiments. For example, in the above embodiments, a component integrally formed by a single member may be replaced with a component divided into a plurality of members and connected or fixed to each other. Additionally, a component formed by connecting a plurality of members may be replaced with a component formed integrally by a single member. In addition, the details described in the embodiments may be appropriately changed without departing from the spirit of the invention.

[0282] For example, in the above embodiments, the configuration in which the correction mechanism 63 holds the base material J on the placement plate 34 from above and applies rotation has been exemplified, but the present invention is not limited thereto.

[0283] For example, instead of the correction mechanism 63, a configuration may also be adopted in which the orientation of the base material J is corrected by rotating the placement plate 34 together with the base material J. In this case, preferably, the correction mechanism performing the rotation rotates the wiper mechanism 61, the auxiliary clamp mechanism 62, the first blower mechanism 64, the second blower mechanism 65, the feed device 40, and the clamp device 50, together with the base stage 30 including the placement plate 34, around the Z-axis with respect to the base 12.

[0284] In addition, the hair planting apparatus 10 may be configured to include a detection device that detects hair for planting M that has been gripped between the two sliding plates 692 and 693 of the first gripping mechanism 69 after the hair planting operation.

[0285] For example, in the case of a configuration including the hair camera 76 as the detection device, the hair camera 76 is preferably arranged to be able to capture an image of the first gripping mechanism 69 at the supply position P2 or the recovery position P3. Additionally, in this case, it is preferable to capture an image from the left side at a height corresponding to the contact surfaces of the two sliding plates 692 and 693.

[0286] In addition, the CPU 101 performs imaging at a timing after completion of the binding operation of the hair for planting M.

[0287] For example, the CPU 101 can detect residual hair for planting M by taking a difference between a captured image of the two sliding plates 692 and 693 at this time and a captured image (sample image) of the two sliding plates 692 and 693 at the same position in a state where the hair for planting M is not gripped.

[0288] In addition, the CPU 101 may control the first gripping mechanism 69 and the second gripping mechanism 70 to perform release of gripping and recovery of the hair for planting M at the recovery position P3 only when residual hair for planting M is detected by the hair camera 76, and may control the first gripping mechanism 69 and the second gripping mechanism 70 to return to the retraction position P0 by omitting the gripping release and recovery operations at the recovery position P3 when no residual hair for planting M is detected.

[0289] In addition, when the CPU 101 detects residual hair for planting M by the hair camera 76, it may control such that, after recovering the residual hair for planting M, operations of supplying and binding the hair for planting M are performed again at the same binding position without moving the binding position of the base material J to the next binding position.

[0290] In addition, when the hair camera 76 is arranged at the supply position P2, if it is confirmed at the supply position P2 that no hair for planting M remains between the two sliding plates 692 and 693, the first gripping mechanism 69 and the second gripping mechanism 70 can be returned to the retraction position P0 without stopping at the recovery position P3, thereby making it possible to speed up a single binding operation.

[0291] On the other hand, when the hair camera 76 is arranged at the recovery position P3, by performing re-detection with the hair camera 76 after the gripping release operation and the recovery operation of the hair for planting M, it is possible to confirm whether the gripping release operation and the recovery operation have been properly performed.

[0292] In this way, by providing the hair camera 76 as a detection device for detecting the hair for planting M remaining between the two sliding plates 692 and 693 of the first gripping mechanism 69, residual hair for planting M can be confirmed, thereby making it possible to properly remove and recover the hair for planting M from the first gripping mechanism 69.

[0293] In addition, when the hair for planting M is detected by the hair camera 76 after the hair planting operation, the CPU 101 controls the release mechanism 72 to perform the gripping release operation of the two sliding plates 692 and 693. Therefore, when the hair for planting M is not detected, the gripping release operation can be omitted, thereby making it possible to speed up the operation.

[0294] Furthermore, when the hair for planting M is detected by the hair camera 76 after the hair planting operation, the CPU 101 controls the recovery device 75 to perform a recovery operation of residual hair for planting M. Therefore, when the hair for planting M is not detected, the recovery operation can be omitted, thereby making it possible to speed up the operation.

[0295] In addition, when the CPU 101 detects the hair for planting M by the hair camera 76 after the hair planting operation, the CPU 101 may control so as to execute a retry of the hair planting operation, thereby suppressing a loss of binding of the hair for planting M to the base material J and making it possible to achieve high-quality hair planting.

[0296] Note that the detection device for detecting the hair for planting M is not limited to the camera. For example, a sensor may be used which detects the presence of hair for planting M between two sliding plates 692 and 693 using other optical elements or the like.

[0297] Alternatively, a sensor that detects the inclination of the sliding plate 692 or 693, or a sensor that detects deflection or pressure fluctuation of the sliding plate 692 or 693, which occur due to the hair for planting M being present between the two sliding plates 692 and 693, may be used.