Abstract: Methods and apparatus for automated brush assembly are disclosed. A method of end-rounding bristle ends with an abrasive surface in random orbital motion relative to bristle tufts held in a movable gripper is described. A novel tuft carrier adapted to hold a plurality of bristle tufts in an arrangement suitable for direct mechanical insertion into the tuft chambers of a brush mold is also described. The tuft carrier has a plurality of tuft insertion cavities and a plurality of movable clamps, each clamp adapted to at least partially occlude one of the cavities when closed. Individual bristle tufts, having a fused end and a rounded or non-rounded bristle end, are transferred from a movable gripper to the tuft carrier by direct mechanical insertion. In addition, an apparatus for direct mechanical insertion of bristle tufts from a tuft carrier into the tuft chambers of a brush mold is described.

Abstract: A transport unit usable in a flexible assembly system and comprising an automatic guided vehicle and a work carrier positioned to the rear thereof. The work carrier is of a U shape with a pair of spaced legs extending from a base and having free ends, each of which rotatably mount tooling for engaging opposite ends of a component of the device to be assembled. Drive mechanism is provided for elevation of the work carrier and rotation of the tooling to orient the component at a desired height and at a desired rotative position for ease of assembly of components thereto. The tooling on the work carrier rotates about an axis and engages a component of the device to be assembled whereby the rotative axis is close to the center of gravity of the device to be assembled to minimize the power requirements in rotation thereof. The transport unit has additional structural features facilitating assembly operations and safety of operation.