Bagged spring production method

Abstract

The invention discloses a bagged spring production method which comprises the following steps: S100, tensioning upper-layer cloth and lower-layer cloth at the same time through a cloth pulling mechanism, and controlling the tension of the cloth to enable the compression ratio to be kept between 70% and 80% when a spring is pushed in; s200, a plurality of parallel independent bags are formed on the tensioned cloth, and the size of each independent bag is 130%-200% of the maximum diameter of the spring; s300, the spring is pushed into the formed independent bag through a push plate, and it is ensured that the spring is pushed in place; s400, the formed cloth bag is pulled to move by a bag position distance in a stepping mode through a walking mechanism; and S500, the step S200 to the step S400 are repeated, a plurality of rows of bagged spring arrays are continuously formed, part of cloth tension is released, and the springs are properly rebounded in bags and stably placed in place.

Description

Technical Field

[0001] This invention relates to the field of pocket spring manufacturing technology, and in particular to a method for producing pocket springs. Background Technology

[0002] Pocket springs, as a common type of elastic support component, are widely used in household products. Compared with traditional springs, pocket springs have advantages such as independent support, no interference between springs, and quiet operation, providing users with a more comfortable experience.

[0003] Currently, existing methods for producing pocket springs suffer from inaccurate fabric tension control during the fabric tensioning stage, leading to unstable compression rates when the spring is pushed in. If the compression rate is too high, the spring may be damaged due to over-compression within the bag, affecting its elasticity and lifespan; if the compression rate is too low, the spring cannot be securely fixed in the bag, easily shifting during subsequent use and resulting in uneven support. Regarding the design of individual bag sizes, some production methods do not fully consider the dimensional characteristics of the spring, resulting in an unreasonable match between the individual bag size and the maximum diameter of the spring. When the individual bag size is too small, the spring is difficult to push in smoothly, increasing production difficulty and scrap rate; when the individual bag size is too large, the spring lacks sufficient constraint within the bag, easily causing wobbling and displacement, affecting the overall performance of the pocket spring and further impacting its performance and stability. Summary of the Invention

[0004] This invention aims to solve at least one of the technical problems existing in the prior art. To this end, this invention proposes a method for producing pocket springs that can solve problems such as inaccurate fabric tension control, unreasonable individual bag size, uncoordinated spring pushing and bag movement, and lack of a step for releasing fabric tension, thereby improving the production quality and efficiency of pocket springs.

[0005] A method for producing pocket springs according to a first aspect of the present invention includes the following steps: S100: The upper and lower layers of fabric are simultaneously tensioned by the fabric pulling mechanism, and the fabric tension is controlled so that the compression rate is maintained between 70% and 80% when the spring is pushed in. S200: A plurality of individual pockets are formed side by side on a taut fabric, the size of which is 130% to 200% of the maximum diameter of the spring; S300: Push the spring into the already formed individual bag using a pusher plate, and ensure that the spring is pushed into place; S400: The pre-formed cloth bag is moved one bag position distance by the walking mechanism; S500: Repeat steps S200 to S400 to continuously form multiple rows of bag spring arrays, release part of the fabric tension, and allow the springs to rebound moderately in the bag and be stably positioned. The method for producing pocket springs according to embodiments of the present invention has at least the following beneficial effects: By precisely controlling the fabric tension, the compression rate of the spring is maintained between 70% and 80% when it is pushed in, effectively avoiding damage or displacement of the spring due to unreasonable compression, thus improving the service life of the spring and the support stability of the pocket spring. Furthermore, the size of the individual bag is designed to be 130% to 200% of the maximum diameter of the spring, allowing the spring to be smoothly pushed into the bag. Simultaneously, the bag body provides good constraint on the spring, preventing spring swaying and displacement, ensuring uniform and stable support of the pocket spring. The use of a high-precision pusher drive device and walking mechanism ensures accurate spring placement and precise stepping movement of the bag, resulting in neatly arranged pocket springs and improved product appearance quality and production efficiency. In addition, after continuously producing multiple rows of pocket spring arrays, releasing part of the fabric tension in a timely manner allows the spring to moderately rebound and stably position itself in the bag, further enhancing the support performance and stability of the pocket spring and improving the overall quality of the product.

[0006] According to some embodiments of the present invention, in step S100, the fabric tension is monitored in real time by a tension sensor, and the tension is dynamically adjusted by a feedback control system, wherein the fabric tension is controlled so that the fabric width shrinkage rate does not exceed 1.5%.

[0007] According to some embodiments of the present invention, in step S200, the individual bag is one of a "U" shape, a semi-circular shape, or a semi-hexagonal shape.

[0008] According to some embodiments of the present invention, in step S300, the front end of the push plate is provided with a clearance groove, and the length of the clearance groove is greater than the depth of the bag, so as to avoid interference with the seam of the bag opening.

[0009] According to some embodiments of the present invention, the width of the clearance groove is adjusted according to the width of the fabric bag and the number of springs to adapt to the production needs of different specifications.

[0010] According to some embodiments of the present invention, the return speed of the push plate is matched with the frictional force between the spring and the push plate to avoid causing the spring to retract.

[0011] According to some embodiments of the present invention, the push plate is always in contact with the inner diameter of the spring when pushing the spring, ensuring that the spring moves in a straight line to the designated position.

[0012] According to some embodiments of the present invention, after the spring is pushed into place, the distance between the outer diameter of the spring and the sealing point of the bag is greater than 10mm.

[0013] According to some embodiments of the present invention, step S300 further includes: S310: The position of the spring in the bag is detected by a vision inspection system. If a positional deviation is found, the push plate parameters are adjusted accordingly.

[0014] According to some embodiments of the present invention, in step S200, sewing or ultrasonic welding is selected according to the spring specifications to form the individual bag. Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0015] The present invention will be further described below with reference to the accompanying drawings and embodiments, wherein: Figure 1 This is a schematic flowchart of a method for producing pocket springs according to an embodiment of the present invention; Figure 2 This is a further flowchart illustrating step S300 in the bag spring production method of this invention. Detailed Implementation

[0016] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0017] In the description of this invention, it should be understood that the orientation descriptions, such as up, down, front, back, left, right, etc., are based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0018] In the description of this invention, "several" means one or more, "more than" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. The use of "first" and "second" in the description is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0019] In the description of this invention, unless otherwise explicitly defined, terms such as "setting," "installation," and "connection" should be interpreted broadly. Those skilled in the art can reasonably determine the specific meaning of these terms in this invention in conjunction with the specific content of the technical solution. In the description of this invention, the terms "one embodiment," "some embodiments," "illustrative embodiment," "example," "specific example," or "some examples," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials, or characteristics described can be combined in any suitable manner in one or more embodiments or examples.

[0020] The technical solution of this invention is a method for producing pocket springs, comprising the following steps: S100: The upper and lower layers of fabric are simultaneously tensioned by the fabric pulling mechanism, and the fabric tension is controlled so that the compression rate is maintained between 70% and 80% when the spring is pushed in. S200: Multiple individual pockets are formed side by side on a taut fabric, the size of which is 130% to 200% of the maximum diameter of the spring; S300: The spring is pushed into the pre-formed individual bag by the push plate, and the spring is pushed into place. S400: The pre-formed cloth bag is moved one bag position distance by the walking mechanism; S500: Repeat steps S200 to S400 to continuously form multiple rows of bag spring arrays, release part of the fabric tension, and allow the springs to rebound moderately in the bag and be stably positioned.

[0021] In a specific embodiment, for step S100: the upper and lower fabric layers are simultaneously tensioned by the fabric pulling mechanism, controlling the fabric tension to maintain the compression rate between 70% and 80% when the spring is pushed in. During production, the fabric pulling mechanism employs a precise tension control system, capable of adjusting the fabric tension in real time according to the spring's specifications and performance requirements. By controlling the compression rate when the spring is pushed in between 70% and 80%, sufficient compression space is ensured within the bag to provide elastic support, while preventing damage from excessive compression and ensuring the spring's lifespan.

[0022] For step S200: Multiple individual bags are formed side-by-side on the tensioned fabric, the size of which is 130% to 200% of the maximum diameter of the spring. The size of the individual bags is precisely designed according to the maximum diameter of the spring. When the size of the individual bags is 130% to 200% of the maximum diameter of the spring, the spring can be smoothly pushed into the bag, and the bag body can provide good restraint for the spring, preventing the spring from shaking or shifting during use, and ensuring that the support effect of the bag spring is uniform and stable.

[0023] For step S300: The spring is pushed into the formed individual bag using a pusher plate, ensuring the spring is pushed into place. The pusher plate uses a high-precision drive device, which can accurately control the pushing force and pushing distance to ensure the spring is completely and accurately pushed into the individual bag. Simultaneously, a sensor is installed on the pusher plate to monitor the spring's pushing status in real time. If the spring is not pushed into place, the pushing parameters are adjusted promptly to ensure production quality.

[0024] For step S400: The formed cloth bag is moved one bag position distance by the walking mechanism. The walking mechanism is driven by a stepper motor, which can achieve precise stepping movement and ensure that the distance the formed cloth bag moves each time is accurate. By precisely controlling the movement distance of the cloth bag, the bag springs can be kept neatly arranged, improving the appearance quality of the product.

[0025] For step S500: Repeat steps S200 to S400 to continuously form multiple rows of pocket spring arrays, releasing some of the fabric tension so that the springs can moderately rebound and stably position themselves in the bag. After continuously producing multiple rows of pocket spring arrays, releasing some of the fabric tension in a timely manner provides the springs with a moderate rebound space, allowing the springs to stably position themselves in the bag, further enhancing the support performance and stability of the pocket springs.

[0026] In some specific embodiments of the present invention, the user first selects upper and lower layer fabrics of suitable specifications and places them on the fabric pulling mechanism. The tension of the fabric is gradually adjusted through the tension control system of the fabric pulling mechanism until the compression rate reaches 75% when the spring is pushed in. During the adjustment process, a tension sensor monitors the fabric tension in real time and feeds the data back to the control system. The control system precisely adjusts the tension of the fabric pulling mechanism based on the feedback data to ensure that the fabric tension remains stable within the set range. Multiple parallel independent bags are formed on the tensioned fabric using a hot-melt welding process. Based on the maximum diameter of the spring (50mm), the size of the independent bag is designed to be 80mm. During the hot-melt welding process, the welding temperature and welding time are controlled to ensure that the welding quality of the independent bags is strong and reliable, while also ensuring that the dimensional accuracy of the independent bags meets the requirements.

[0027] Then, a pusher plate is used to push the springs into the pre-formed individual bags. The pusher plate is driven by a servo motor, which can precisely control the pushing speed and force. A pressure sensor is installed on the pusher plate to monitor the pressure changes during the spring pushing process in real time. When the pressure reaches the set value, it indicates that the spring has been pushed into place, and the pusher plate stops pushing. A stepper motor-driven walking mechanism pulls the pre-formed cloth bag one bag position distance. According to the size and arrangement requirements of the individual bags, the step angle and number of rotations of the stepper motor are set to ensure that the distance the cloth bag moves each time is accurately the width of the individual bag. During the movement, a photoelectric sensor is used to detect the position of the cloth bag to ensure movement accuracy. Steps S200 to S400 are repeated to continuously form multiple rows of bag spring arrays. After producing 10 rows of bag springs, the tension of the fabric is slowly released through the tension release device of the fabric pulling mechanism, allowing the springs to rebound moderately in the bag. The state of the springs in the bag is observed to ensure that the springs are stably positioned without shaking or displacement.

[0028] In other embodiments, the user also selects upper and lower fabric layers, which are tensioned using a fabric pulling mechanism. By adjusting the parameters of the fabric pulling mechanism, the compression rate is controlled at 70% when the spring is pushed in. During the tensioning process, multiple fine adjustments are made to gradually reach the set compression rate, ensuring uniform and stable fabric tension. Individual bags are manufactured using ultrasonic welding. Based on the maximum spring diameter of 60mm, the size of the individual bag is set to 90mm. During ultrasonic welding, the welding frequency and welding pressure are optimized to improve the welding quality and production efficiency of the individual bags. The pusher plate is driven by a cylinder, and the pushing force is controlled by adjusting the cylinder's air pressure. A displacement sensor is installed on the pusher plate to monitor the pushing displacement in real time. When the displacement reaches the depth of the individual bag, it is determined that the spring has been pushed in place. Simultaneously, throttle valves are installed at the air inlet and outlet of the cylinder to adjust the cylinder's movement speed, ensuring a smooth and stable spring pushing process. The walking mechanism is driven by a linear motor, enabling high-speed and precise stepping movement. According to production requirements, the motion parameters of the linear motor are set so that the formed bag moves one bag position distance each time. During the movement, an encoder provides real-time feedback on the linear motor's position to ensure a movement accuracy of ±0.1mm. Finally, following steps S200 to S400, multiple rows of bag spring arrays are continuously produced. After producing eight rows, some fabric tension is released. The tension is released gradually, releasing small amounts of tension each time, observing the spring's rebound to ensure the spring is stably positioned within the bag, while avoiding excessive spring rebound due to rapid tension release.

[0029] Understandably, this invention, by precisely controlling the fabric tension, maintains the compression rate of the spring between 70% and 80% during insertion, effectively avoiding damage or displacement caused by unreasonable compression rates, thus improving the spring's lifespan and the support stability of the bag springs. Furthermore, designing the size of the individual bag to be 130% to 200% of the spring's maximum diameter allows the spring to be smoothly pushed into the bag, while the bag body provides good constraint, preventing spring swaying and displacement, ensuring uniform and stable support from the bag springs. The use of a high-precision pusher drive device and walking mechanism ensures accurate spring placement and precise stepping movement of the bag, resulting in neatly arranged bag springs, improving product appearance quality and production efficiency. Additionally, after continuously producing multiple rows of bag spring arrays, releasing some fabric tension in a timely manner allows the springs to moderately rebound and stably position themselves within the bag, further enhancing the support performance and stability of the bag springs and improving the overall product quality.

[0030] In some embodiments, high-precision tension sensors are installed at key locations of the fabric spreading mechanism. These sensors can sense the tension on the fabric in real time and transmit the data to the feedback control system in the form of electrical signals. The feedback control system employs an advanced PID control algorithm, pre-setting parameters such as the target fabric tension value and a fabric width shrinkage rate not exceeding 1.5%. During production, when the tension sensor detects that the fabric tension deviates from the target value, the feedback control system quickly analyzes the deviation and calculates the corresponding adjustment amount according to the PID algorithm. It then controls the drive device of the fabric spreading mechanism, such as a motor or cylinder, to dynamically adjust the stretching or relaxing of the fabric, ensuring that the fabric tension remains within the set range while guaranteeing that the fabric width shrinkage rate does not exceed 1.5%. For example, when producing a certain specification of pocket springs, if the target fabric tension is set to 50N, and the tension sensor detects an actual tension of 55N, the feedback control system calculates the need to reduce the tension by 5N and controls the fabric spreading mechanism to appropriately relax the fabric, restoring the tension to 50N.

[0031] Understandably, by monitoring fabric tension in real time with a tension sensor and dynamically adjusting the tension using a feedback control system, the fabric tension can be precisely controlled, ensuring the stability of the compression rate when the spring is pushed in. Simultaneously, strictly controlling the fabric width shrinkage rate to no more than 1.5% avoids problems such as spring misalignment or uneven force distribution within the bag due to excessive fabric shrinkage, thus improving the production quality and consistency of bagged springs and reducing the scrap rate.

[0032] Furthermore, the shape of the individual pockets is selected based on different product needs and design requirements. If a "U"-shaped individual pocket is chosen, a hot-melt welding process is used to weld multiple parallel "U"-shaped individual pockets onto the taut fabric according to the pre-set "U" shape. If a semi-circular individual pocket is chosen, a semi-circular groove is stamped into the fabric using a die, and then the edges of the groove are closed by sewing or hot-melt welding to form an individual pocket. If a semi-hexagonal individual pocket is chosen, a semi-hexagonal outline is first marked on the fabric, and then ultrasonic welding technology is used to weld along the outline to form an individual pocket. For example, when producing pocket springs for a high-end mattress, to provide better support and comfort, a semi-hexagonal individual pocket is chosen. The efficiency and strength of ultrasonic welding are used to quickly and accurately produce multiple semi-hexagonal individual pockets.

[0033] It should be noted that various individual bag shapes are available, including "U"-shaped, semi-circular, and semi-hexagonal, to meet the different requirements of various products for spring support performance and appearance. The "U"-shaped individual bag has a simple structure, is easy to manufacture, and has a lower cost; the semi-circular individual bag can better conform to the shape of the spring, providing more even support; the semi-hexagonal individual bag combines the advantages of both, ensuring support performance while also being aesthetically pleasing, thus improving product diversity and market competitiveness.

[0034] Reference Figure 1 Regarding the push plate mentioned in step S300, a clearance groove is created at the front end of the push plate during its design. Based on the actual depth of the fabric bag in production, the length of the clearance groove is set to be greater than the bag depth; for example, if the bag depth is 30mm, the clearance groove length is set to 35mm. Simultaneously, the shape and size of the clearance groove are rationally designed to smoothly avoid the bag opening seam. When pushing the spring, the push plate moves forward, and the clearance groove enters the bag first, avoiding interference between the front end of the push plate and the bag opening seam, ensuring the spring can be smoothly pushed into the individual bag. For example, in producing pocket springs for sofa cushions, because sofa cushions require high spring alignment accuracy, the clearance groove effectively avoids problems such as unsmooth spring pushing or positional misalignment caused by interference from the bag opening seam. The clearance groove at the front end of the push plate, with its length greater than the bag depth, effectively avoids interference between the push plate and the bag opening seam, ensuring smooth and accurate spring pushing. This reduces production failures and scrap rates caused by interference, improves production efficiency and product quality, and simultaneously reduces equipment maintenance costs.

[0035] Furthermore, the width of the clearance groove can be adjusted according to the production requirements of different specifications. When producing small-sized pocket springs, the pocket width is narrower and the number of springs is smaller, so the clearance groove width is set to a smaller value, such as 10mm. When producing large-sized pocket springs, the pocket width is wider and the number of springs is larger, so the clearance groove width is set to a larger value, such as 20mm. By adjusting the width of the clearance groove, it can adapt to the production requirements of different widths of pockets and different numbers of springs, ensuring that the pusher plate always avoids the pocket opening seam during the spring pushing process. For example, when producing pocket springs for an adjustable firmness mattress, it is necessary to adjust the number and arrangement of springs according to different firmness requirements. By flexibly adjusting the width of the clearance groove, the needs of diversified production are met. The width of the clearance groove is adjusted according to the width of the pocket and the number of springs, which enhances the adaptability and versatility of the pusher plate and can meet the production needs of pocket springs of different specifications. There is no need to design different models of pusher plates for different specifications of products, which reduces production costs and production cycle, improves production efficiency and the company's market responsiveness.

[0036] It should be noted that the matching relationship between the pusher plate's return speed and the frictional force between the spring and the pusher plate was determined through experiments and calculations. First, the frictional force between springs of different materials and specifications and the pusher plate was measured. Then, the pusher plate's return speed was adjusted according to the magnitude of the frictional force. For example, when the frictional force between the spring and the pusher plate is 5N, the pusher plate's return speed is set to 0.5m / s to ensure that during the pusher plate's return process, sufficient inertial force will not be generated due to excessive speed, causing the spring to retract. In actual production, the spring's position is monitored in real time using sensors. If any signs of spring retraction are detected, the pusher plate's return speed parameter is adjusted promptly. It is understandable that by matching the pusher plate's return speed to the frictional force between the spring and the pusher plate, the spring's retraction during pusher plate return can be effectively prevented, ensuring the spring's positional stability within the individual bag. This improves the production quality of bagged springs, reduces defective products caused by spring retraction, and lowers production costs and rework rates.

[0037] It's important to note that the shape and size of the pusher plate remain in contact with the spring's inner diameter during spring pushing. For example, the front end of the pusher plate is designed to be cylindrical or conical, matching the spring's inner diameter. During pushing, the pusher plate accurately inserts into the spring's inner diameter, providing stable support and guidance, ensuring the spring moves in a straight line to the designated position. Simultaneously, guide devices, such as guide rails or sliders, are installed on the pusher plate to further ensure the linearity of its movement. For instance, in the production of pocket springs for high-precision medical mattresses, this design ensures the springs are accurately pushed into individual pockets, meeting the stringent precision and quality requirements of medical products. The pusher plate's constant contact with the spring's inner diameter provides precise guidance and support, ensuring the spring moves in a straight line to the designated position, improving the accuracy and stability of spring pushing. This reduces spring offset and wobbling during pushing, ensuring the neatness of the pocket springs' arrangement and the consistency of their support performance, thus improving the overall quality of the product.

[0038] In some embodiments, after the spring is pushed into position, the distance between the spring's outer diameter and the bag's seal is precisely measured using a measuring tool to ensure that this distance is greater than 10mm. For example, a vernier caliper is used for measurement. If the measured distance is less than 10mm, the pushing parameters of the pusher plate or the size of the individual bag are adjusted, and the spring pushing operation is repeated until the distance requirement is met. In actual production, a quality inspection process is set up to test this distance for each pocketed spring to ensure that the product quality meets the standards. For example, when producing a pocketed spring for a high-end mattress for export, production and testing are strictly carried out according to this standard, ensuring the product's competitiveness in the international market. Ensuring that the distance between the spring's outer diameter and the bag's seal is greater than 10mm after the spring is pushed into position provides sufficient space for the spring to rebound appropriately within the bag, while avoiding friction and collision between the spring and the bag's seal, reducing spring wear and noise. This improves the lifespan and comfort of the pocketed spring, enhancing the product's market competitiveness.

[0039] Reference Figure 2 Step S300 also includes: S310: The position of the spring in the bag is detected by a vision inspection system. If a positional deviation is found, the push plate parameters are adjusted accordingly.

[0040] Specifically, the user installs a vision inspection system, which includes a high-definition camera and image processing software. During the spring pushing process, the high-definition camera captures real-time images of the spring's position in the bag and transmits these images to the image processing software. The image processing software analyzes and processes the images, identifies the spring's position information, and compares it with a preset standard position. If the spring's position deviation exceeds the allowable range, it provides feedback to adjust the pusher parameters, such as pushing speed, pushing force, or pushing direction. For example, when the vision inspection system detects that the spring has shifted 2mm to the left in the bag, the image processing software feeds the deviation information back to the control system, which then adjusts the pusher's pushing direction, making a slight adjustment to the right to ensure the spring is accurately pushed into the designated position. It can be understood that by using a vision inspection system to detect the spring's position in the bag and promptly providing feedback to adjust the pusher parameters, automated and intelligent control of spring pushing can be achieved, improving the accuracy and consistency of spring pushing. This reduces errors and workload associated with manual inspection, increases production efficiency and product quality, and lowers production costs.

[0041] It's important to note that the appropriate molding process for creating individual pockets is chosen based on the spring's specifications. When the spring diameter is small and its strength is low, sewing is used. A high-speed sewing machine is used to sew the fabric according to a pre-set pattern to create an individual pocket. Sewing is low-cost and simple to operate, making it suitable for producing small-sized springs. When the spring diameter is large and its strength is high, ultrasonic welding is chosen. The high-frequency vibration of ultrasound generates frictional heat between fabric molecules, achieving welding and creating an individual pocket. Ultrasonic welding offers strong welds and good sealing, meeting the strength requirements of large-sized springs for individual pockets. For example, when producing pocket springs for a children's mattress, where the strength requirement is low, sewing is chosen for creating the individual pockets. However, when producing pocket springs for a heavy-duty truck seat, where the seat requires higher spring support strength, ultrasonic welding is chosen for creating the individual pockets.

[0042] Understandably, choosing between sewing or ultrasonic welding to create individual bags based on spring specifications leverages the advantages of both processes, meeting the performance requirements of different spring sizes. Sewing is low-cost and suitable for producing small-sized springs, while ultrasonic welding offers high-quality welds and is suitable for producing large-sized springs. This improves the manufacturing quality and efficiency of individual bags, reduces production costs, and enhances the product's market adaptability.

[0043] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A method for producing pocket springs, characterized in that, Includes the following steps: S100: The upper and lower layers of fabric are simultaneously tensioned by the fabric pulling mechanism, and the fabric tension is controlled so that the compression rate is maintained between 70% and 80% when the spring is pushed in. S200: A plurality of individual pockets are formed side by side on a taut fabric, the size of which is 130% to 200% of the maximum diameter of the spring; S300: Push the spring into the already formed individual bag using a pusher plate, and ensure that the spring is pushed into place; S400: The pre-formed cloth bag is moved one bag position distance by the walking mechanism; S500: Repeat steps S200 to S400 to continuously form multiple rows of bag spring arrays, release part of the fabric tension, and allow the springs to rebound moderately in the bag and be stably positioned.

2. The method for producing pocket springs according to claim 1, characterized in that, In step S100, the fabric tension is monitored in real time by a tension sensor, and the tension is dynamically adjusted by a feedback control system. The fabric tension is controlled so that the fabric width shrinkage rate does not exceed 1.5%.

3. The method for producing pocket springs according to claim 1, characterized in that, In step S200, the individual bag is one of the following shapes: "U", semi-circular, or semi-hexagonal.

4. The method for producing pocket springs according to claim 1, characterized in that, In step S300, the front end of the push plate is provided with a clearance groove, and the length of the clearance groove is greater than the depth of the bag, so as to avoid interference with the seam of the bag opening.

5. The method for producing pocket springs according to claim 4, characterized in that, The width of the air-avoiding groove is adjusted according to the width of the fabric bag and the number of springs to meet the production needs of different specifications.

6. The method for producing pocket springs according to claim 1, characterized in that, The return speed of the push plate is matched with the frictional force between the spring and the push plate to avoid causing the spring to retract.

7. The method for producing pocket springs according to claim 1, characterized in that, The push plate always contacts the inner diameter of the spring when pushing it, ensuring that the spring moves in a straight line to the designated position.

8. The method for producing pocket springs according to claim 1, characterized in that, After the spring is pushed into place, the distance between the outer diameter of the spring and the sealing point of the bag is greater than 10mm.

9. The method for producing pocket springs according to claim 1, characterized in that, Step S300 further includes: S310: The position of the spring in the bag is detected by a vision inspection system. If a positional deviation is found, the push plate parameters are adjusted accordingly.

10. The method for producing pocket springs according to claim 1, characterized in that, In step S200, sewing or ultrasonic welding is selected according to the spring specifications to form the individual bag.

Images