Automatic mattress processing production line and production method

Abstract

The invention discloses an automatic mattress processing production line and a production method. The production line comprises a collecting and stacking machine, a first belt conveyor, an edging and stacking machine, a fillet cutting machine, a second belt conveyor and a third belt conveyor. The production method comprises the steps of checking a working state and confirming that each unit of equipment is at an initial position; an electric control system is started for self-inspection, a production requirement parameter setting scheme is imported, and an automatic machining production process is executed; and parameters of automatic stacking, automatic weighing and automatic cutting procedures are judged, and products with unqualified weights are distributed. The whole production line comprises the collecting and stacking machine, the first belt conveyor, the edging and stacking machine, the fillet cutting machine, the second belt conveyor and the third belt conveyor, continuous automatic operation from weight detection, stacking and stacking to fillet machining of mattresses is achieved, the production efficiency is effectively improved, manual intervention is reduced, the product quality stability is ensured, and the production cost is reduced. And the device is suitable for producing mattresses with various materials and sizes.

Description

Technical Field

[0001] This invention relates to the field of mattress processing and manufacturing technology, and in particular to an automated mattress processing production line and manufacturing method. Background Technology

[0002] A mattress is a bedding product placed between the human body and the bed, mainly used to improve sleep comfort and support the body. Materials include springs, palm fiber, latex, 3D materials, etc. Modern mattress design focuses on differentiated support and health protection, such as independent pocket spring structure to improve anti-interference, materials to enhance environmental protection through glue-free processes, and latex material with both antibacterial and breathable properties.

[0003] At the existing environmentally friendly palm fiber production line, workers are required to participate in the entire production process at the material receiving and corner rounding stations. In the material receiving stage, workers need to constantly monitor the equipment's operating status, control the pace the moment the product leaves the production line, and manually collect and neatly stack the formed environmentally friendly palm fiber products one by one to ensure stable stacking and prevent tipping. At the corner rounding station, workers are required to simultaneously operate the cutting equipment, accurately align the four corners of the product before starting the cutting program, and check the cutting effect in real time. Due to the limitations of human strength and skill, the speed of manual operation is difficult to match the rhythm of automated equipment operation, often resulting in delays in process connection. This can easily lead to bumps and deformation of product corners, as well as problems such as incorrect cutting dimensions and rough edges, directly increasing material waste and the rate of defective products. Summary of the Invention

[0004] The purpose of this invention is to address the shortcomings of existing technologies by proposing an automated mattress production line and production method.

[0005] To achieve the above objectives, in a first aspect, the present invention provides an automated mattress manufacturing production line, comprising:

[0006] A stacking machine includes a stacking truss and a first conveyor frame. The stacking truss is equipped with a stacking collection component, and the first conveyor frame is equipped with a first conveying component and a stacking pushing component for collecting and stacking mattresses to be processed.

[0007] The first belt conveyor includes a second conveyor frame, on which a second conveyor assembly, a first lifting and steering assembly, and a conveying and weighing assembly are provided for diverting mattresses that do not meet the weight requirements.

[0008] The edge-aligning stacking machine includes an edge-aligning truss and a third conveyor frame. The edge-aligning truss is equipped with an edge-aligning stacking component, and the third conveyor frame is equipped with a third conveying component, an edge-aligning lifting component, and an edge-aligning pushing component for aligning mattresses to be processed.

[0009] A corner rounding cutter includes a fourth conveyor frame, on which a fourth conveyor assembly, a corner rounding cutter assembly, and a corner rounding limit assembly are provided for cutting the edges of a mattress;

[0010] The second belt conveyor includes a fifth conveyor frame, on which a fifth conveyor assembly and a second lifting and steering assembly are provided for conveying the processed mattress;

[0011] The mattresses to be processed are sequentially stacked, sorted, processed, and transported through a collection and stacking machine, a first belt conveyor, an edge-trimming stacking machine, a corner-rounding cutter, and a second belt conveyor.

[0012] In some embodiments, the first conveying assembly includes a first conveying motor, the output end of which is rotatably connected to a first conveying roller, and the first conveying roller is rotatably connected to a first conveyor belt;

[0013] The collection and stacking assembly includes a first gear and rack assembly, which is symmetrically mounted on the stacking truss. A second gear and rack assembly is mounted on the top of the first gear and rack assembly via a sliding seat, and a first cylinder gripper assembly is mounted on the bottom of the second gear and rack assembly via a clamping frame.

[0014] The collection and pushing component includes a first pushing plate, the end of which is connected to a first sliding guide rail assembly via a first pushing frame, and a first pushing motor is installed on one side of the first sliding guide rail assembly.

[0015] In some embodiments, the second conveying assembly includes a second conveying motor, the output end of which is rotatably connected to a second conveying roller, and the second conveying roller is rotatably connected to a second conveyor belt;

[0016] The first lifting and steering assembly includes a first lifting bogie, a first lifting cylinder symmetrically mounted on the bottom of the first lifting bogie, a first rotating roller mounted on the top of the first lifting bogie, a first steering motor mounted inside the first lifting bogie, and the first steering motor rotatably connected to the first rotating roller.

[0017] The conveying and weighing assembly includes a pressure sensor, which is symmetrically installed at the bottom of the second conveyor frame.

[0018] In some embodiments, the third conveying assembly includes a third conveying motor, the output end of which is rotatably connected to a third conveying roller, and the third conveying roller is rotatably connected to a third conveyor belt;

[0019] The edge-aligning stacking assembly includes a third gear rack assembly, which is symmetrically mounted on the edge-aligning truss. A first linear bearing assembly is mounted on the top of the third gear rack assembly via an edge-aligning seat, and a second cylinder gripper assembly is mounted on the bottom of the first linear bearing assembly via an edge-aligning frame.

[0020] In some embodiments, the edge-aligning lifting assembly includes an edge-aligning lifting frame, a second linear bearing assembly is mounted on the top of the edge-aligning lifting frame via a lifting seat, and edge-aligning lifting cylinders are symmetrically mounted on the bottom of the edge-aligning lifting frame.

[0021] The edge-aligning push assembly includes a second push plate, which is symmetrically installed on both sides of the third conveyor frame. The end of the edge-aligning push plate is connected to the second sliding guide rail assembly through the second push frame. A second push cylinder is installed on one side of the second sliding guide rail assembly.

[0022] In some embodiments, the fourth conveying assembly includes a fourth conveying motor, the output of which is rotatably connected to a fourth conveying roller, and the fourth conveying roller is rotatably connected to a fourth conveyor belt;

[0023] The rounded corner cutting assembly includes a rounded corner moving frame. A third sliding guide rail assembly is mounted on the bottom of the rounded corner moving frame via a cutting seat. A set of fourth sliding guide rail assemblies is mounted on the third sliding guide rail assembly, and a fifth sliding guide rail assembly is mounted on one side of the third sliding guide rail assembly.

[0024] In some embodiments, a set of rounded corner cutting devices are symmetrically installed on both sides of the feed end of the fourth conveyor frame via a fourth sliding guide assembly, and a first cutting motor is installed on one side of the fourth sliding guide assembly. A set of rounded corner cutting devices are symmetrically installed on both sides of the discharge end of the fourth conveyor frame via a fifth sliding guide assembly, and a second cutting motor is installed on one side of the fifth sliding guide assembly.

[0025] The rounded corner limiting assembly includes a limiting plate, a limiting cylinder is installed above the limiting plate, and a pressure plate is installed at the end of the limiting cylinder.

[0026] In some embodiments, the fifth conveying assembly includes a fifth conveying motor, the output end of which is rotatably connected to a fifth conveying roller, and the fifth conveying roller is rotatably connected to a fifth conveyor belt;

[0027] The second lifting and steering assembly includes a second lifting bogie, with a second lifting cylinder symmetrically mounted on the bottom of the second lifting bogie and a second rotating roller mounted on the top of the second lifting bogie.

[0028] In some embodiments, a third belt conveyor is also included, which is disposed on one side of the collecting stacker and / or the first belt conveyor. The third belt conveyor includes a sixth conveyor frame on which a sixth conveying assembly is disposed for conveying defective mattresses.

[0029] The sixth conveying assembly includes a sixth conveying motor, the output end of which is rotatably connected to a sixth conveying roller, and the sixth conveying roller is rotatably connected to a sixth conveyor belt.

[0030] In a second aspect, the present invention also provides an automated mattress manufacturing method, executed via an automated mattress manufacturing production line as described in the first aspect, the method comprising:

[0031] Check the working status of the stacker, first belt conveyor, edge trimming stacker, corner rounding cutter, second belt conveyor, and third belt conveyor, and confirm that each unit of the equipment is in its initial position;

[0032] Start the electrical control system to perform a self-test, import the production requirement parameter settings, and execute the automatic processing production process;

[0033] Determine the parameters of automatic palletizing, automatic weighing, and automatic cutting processes, and sort out products that do not meet the weight requirements.

[0034] The present invention has the following beneficial effects:

[0035] The entire production line of this invention includes a collection and stacking machine, a first belt conveyor, an edge-trimming stacking machine, a corner rounding cutter, a second belt conveyor, and a third belt conveyor, realizing continuous automated operation of mattresses from weight detection, stacking and placement to corner rounding processing, effectively improving production efficiency, reducing manual intervention, ensuring product quality stability, and is suitable for the production of mattresses of various materials and sizes. Attached Figure Description

[0036] Figure 1 This is a schematic diagram of the automatic mattress processing production line proposed in this invention;

[0037] Figure 2 This is a front view of the automated mattress production line proposed in this invention;

[0038] Figure 3 This is a top view of the automated mattress production line proposed in this invention;

[0039] Figure 4 for Figure 2 Enlarged diagram corresponding to point A in the middle;

[0040] Figure 5 for Figure 2 Enlarged diagram corresponding to point B in the middle;

[0041] Figure 6 for Figure 2 Enlarged diagram corresponding to point C in the middle;

[0042] Figure 7 for Figure 2 Enlarged diagram corresponding to point D in the middle;

[0043] Figure 8 for Figure 2 Enlarged view of point E in the middle;

[0044] Figure 9 for Figure 2 Enlarged schematic diagram corresponding to point F in the middle;

[0045] Figure 10 for Figure 2 Enlarged schematic diagram corresponding to point G in the middle;

[0046] Figure 11 for Figure 2 Enlarged schematic diagram corresponding to point H in the middle;

[0047] Figure 12 for Figure 2 Enlarged schematic diagram corresponding to point I in the middle.

[0048] Legend:

[0049] 1. Stacking machine; 11. Stacking truss; 12. First conveyor frame; 13. Stacking assembly; 131. First gear and rack assembly; 132. Sliding seat; 133. Second gear and rack assembly; 134. Clamping frame; 135. First cylinder gripper assembly; 14. First conveyor assembly; 141. First conveyor motor; 142. First conveyor roller; 143. First conveyor belt; 15. Stacking and pushing assembly; 151. First pusher plate; 152. First pusher frame; 153. First sliding guide rail assembly; 154. First pusher motor; 2. First belt conveyor; 21. Second conveyor frame; 22. Second conveyor assembly; 221. Second conveyor motor; 222 223. Second conveyor roller; 23. Second conveyor belt; 23. First lifting and steering assembly; 231. First lifting bogie; 232. First lifting cylinder; 233. First rotating roller; 234. First steering motor; 24. Conveying weighing assembly; 241. Pressure sensor; 3. Edge trimming stacking machine; 31. Edge trimming truss; 32. Third conveyor frame; 33. Edge trimming stacking assembly; 331. Third gear and rack assembly; 332. Edge trimming seat; 333. First linear bearing assembly; 334. Edge trimming frame; 335. Second cylinder gripper assembly; 34. Third conveying assembly; 341. Third conveyor motor; 342. Third conveyor roller; 343. Third conveyor belt; 35. Edge trimming... Lifting assembly; 351, Edge-following lifting frame; 352, Lifting seat; 353, Second linear bearing assembly; 354, Edge-following lifting cylinder; 36, Edge-following pushing assembly; 361, Second pushing plate; 362, Second pushing frame; 363, Second sliding guide rail assembly; 364, Second pushing cylinder; 4, Rounded corner cutting machine; 41, Fourth conveyor frame; 42, Fourth conveyor assembly; 421, Fourth conveyor motor; 422, Fourth conveyor roller; 423, Fourth conveyor belt; 43, Rounded corner cutting assembly; 431, Rounded corner moving frame; 432, Cutting seat; 433, Third sliding guide rail assembly; 434, Fourth sliding guide rail assembly; 435, Fifth sliding guide rail assembly; 436 437. First cutting motor; 438. Second cutting motor; 439. Rounded corner cutting device; 440. Rounded corner limiting assembly; 441. Limiting plate; 442. Limiting cylinder; 443. Lower pressure plate; 5. Second belt conveyor; 51. Fifth conveyor frame; 52. Fifth conveyor assembly; 521. Fifth conveyor motor; 522. Fifth conveyor roller; 523. Fifth conveyor belt; 53. Second lifting and steering assembly; 531. Second lifting bogie; 532. Second lifting cylinder; 533. Second rotating roller; 6. Third belt conveyor; 61. Sixth conveyor frame; 62. Sixth conveyor assembly; 621. Sixth conveyor motor; 622. Sixth conveyor roller; 623. Sixth conveyor belt. Detailed Implementation

[0050] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0051] This application provides an automated mattress production line and method, solving the problems in existing technologies where manual operation speed is limited by factors such as physical strength and skill level, making it difficult to fully match the automated operation rhythm of the equipment, often resulting in delayed process connections; and easily leading to product edge damage, deformation, and problems such as inconsistent cutting dimensions and rough edges, directly increasing material waste and defective product rates. The entire production line of this application includes a collection and stacking machine, a first belt conveyor, an edge-trimming stacking machine, a corner-rounding cutter, a second belt conveyor, and a third belt conveyor, realizing continuous automated operation of mattresses from weight detection and stacking to corner rounding processing, effectively improving production efficiency, reducing manual intervention, ensuring product quality stability, and is suitable for the production of mattresses of various materials and sizes.

[0052] Please refer to the following examples for details:

[0053] Reference Figures 1-12 The present invention provides an embodiment of an automated mattress processing production line, the specific structure of which includes: a collecting and stacking machine 1, a first belt conveyor 2, an edge-trimming stacking machine 3, a corner-rounding cutter 4, a second belt conveyor 5, and a third belt conveyor 6.

[0054] The process involves several steps. First, the mattresses are initially collected and stacked by a stacking machine 1. Then, a first belt conveyor 2 precisely transports them to an edge-aligning stacking machine 3 for edge alignment, ensuring dimensional consistency in subsequent processing. The aligned mattresses are then conveyed to a corner rounding cutter 4 for corner rounding. Finally, a second belt conveyor 5 transports the qualified mattresses to the next stage (such as packaging or finished product storage), achieving seamless integration of all processes. During processing, if a mattress is found to have a weight that does not meet the preset standard (e.g., exceeding or falling below the acceptable weight range), or if there are still dimensional deviations or substandard corner rounding accuracy after edge alignment, these defective mattresses are guided and diverted by a diversion mechanism on the first and second belt conveyors 2 and 5. Finally, a third belt conveyor 6 collects them and returns them to the defective product processing area for rework or waste disposal, effectively preventing defective products from being mixed with qualified products.

[0055] For example, please continue reading Figures 1-12In this embodiment, the stacking machine 1 includes a stacking truss 11 and a first conveyor frame 12. The stacking truss 11 is provided with a stacking collection assembly 13, and the first conveyor frame 12 is provided with a first conveyor assembly 14 and a stacking push assembly 15, for collecting and stacking mattresses to be processed.

[0056] Furthermore, the first conveying assembly 14 includes a first conveying motor 141 (the speed of which can be adjusted according to the rhythm of subsequent processes to adapt to different processing efficiency requirements). The output end of the first conveying motor 141 is rotatably connected to the first conveying roller 142, and the first conveying roller 142 is rotatably connected to the first conveyor belt 143. This allows the first conveying motor 141 to drive the first conveying roller 142 to rotate, thereby driving the first conveyor belt 143 to continuously convey the mattress to be processed.

[0057] Furthermore, the stacking assembly 13 includes a first gear and rack assembly 131, which is symmetrically mounted on the stacking truss 11. A second gear and rack assembly 133 (perpendicularly distributed to the first gear and rack assembly 131, enabling horizontal and vertical movement respectively) is mounted on the top of the first gear and rack assembly 131 via a sliding seat 132. A first cylinder gripper assembly 135 (with a flexible silicone pad attached to the inside of the gripper to avoid pinching the mattress) is mounted on the bottom of the second gear and rack assembly 133 via a clamping frame 134.

[0058] In actual operation, the movement of the first gear and rack assembly 131 and the second gear and rack assembly 133 can be controlled by two servo drive motors respectively: the first gear and rack assembly 131 drives the sliding seat 132 and the second gear and rack assembly 133 to move horizontally, while the second gear and rack assembly 133 drives the clamping frame 134 and the first cylinder gripper assembly 135 to move vertically; at the same time, a position sensor is also installed on the first conveyor frame 12 (as prior art). Figures 1-3 (Not shown in the image) The system monitors the entry position and conveying status of the mattress to be processed in real time and transmits the signal to the control system. The control system precisely controls the operation of the drive motor based on the position information fed back by the sensor, thereby driving the first cylinder gripper assembly 135 to achieve coordinated lifting, lowering and forward and backward movement. When the mattress reaches the preset gripping position, the first drive cylinder drives the first gripper to close synchronously, gripping the mattress with a preset gripping pressure (which can be adjusted according to the mattress thickness, for example, 50-80N), and stacking it according to the preset number of layers (for example, 3 layers / stack), ultimately realizing the automated gripping and orderly stacking of the mattress to be processed.

[0059] Furthermore, the collection and pushing component 15 includes a first pushing plate 151, the end of which is connected to a first sliding guide rail assembly 153 via a first pushing frame 152, and a first pushing motor 154 is installed on one side of the first sliding guide rail assembly 153.

[0060] After the stacking assembly 13 completes the stacking of the mattresses to a preset number of layers, the control system sends a start signal to the first push motor 154. The first push motor 154 is powered on and drives the first push frame 152 to slide along the first sliding guide rail assembly 153 at a steady speed (e.g., 0.5 m / s). The sliding push frame further drives the first push plate 151 to move synchronously, accurately pushing the neatly stacked mattresses onto the conveyor belt of the first belt conveyor 2. After the push is completed, the first push motor 154 reverses its rotation, driving the first push plate 151 to reset, preparing for the next push action.

[0061] For example, please continue reading Figures 1-12 In this embodiment, the first belt conveyor 2 includes a second conveyor frame 21, on which a second conveying component 22, a first lifting and steering component 23 and a conveying weighing component 24 are provided for diverting mattresses that do not meet the weight requirements.

[0062] Furthermore, the second conveying assembly 22 includes a second conveying motor 221, the output end of which is rotatably connected to the second conveying roller 222, and the second conveying roller 222 is rotatably connected to the second conveyor belt 223, so that the second conveying motor 221 can drive the second conveying roller 222 to rotate, thereby driving the second conveyor belt 223 to continuously convey the stacked mattresses.

[0063] Furthermore, the first lifting and steering assembly 23 includes a first lifting bogie 231 (which may be made of lightweight alloy material to reduce lifting load). First lifting cylinders 232 are symmetrically installed at the four bottom corners of the first lifting bogie 231. Multiple sets of first rotating rollers 233 are installed in parallel on the top of the first lifting bogie 231. A first steering motor 234 is also fixedly installed inside the first lifting bogie 231 (the motor is connected to the first rotating rollers 233 via a synchronous belt).

[0064] When the conveying weighing component 24 detects that the mattress weight is unqualified, the control system immediately sends signals to the first lifting cylinder 232 and the first steering motor 234: the first lifting cylinder 232 is first energized to push the first lifting steering frame 231 to rise and fall until the top of the first rotating roller 233 is higher than the surface of the second conveyor belt 223 (ensuring that the mattress can be lifted). Then the first steering motor 234 starts, driving all the first rotating rollers 233 to rotate synchronously (the rotation direction is 90° with the conveying direction of the second conveyor belt 223), and smoothly guides the unqualified mattresses to the third belt conveyor 6, realizing the rapid diversion of unqualified products; after the diversion is completed, the first lifting cylinder 232 drives the first lifting steering frame 231 to reset, the first steering motor 234 stops running, and waits for the next diversion command;

[0065] Furthermore, the conveying and weighing assembly 24 includes a pressure sensor 241, which is symmetrically installed at the four support legs at the bottom of the second conveyor frame 21.

[0066] In actual operation, when the mattress stack passes the second conveyor belt 223, its weight is evenly transferred to the second conveyor frame 21, and then accurately sensed by the pressure sensor 241. The sensor converts the sensed weight signal into an electrical signal and transmits it to the PLC control system of the control cabinet through a shielded cable (to avoid external electromagnetic interference). The control system compares the real-time weight signal with the preset weight acceptable range (e.g., 5-10kg). If the weight is within the acceptable range, the mattress stack continues to be conveyed to the edge-trimming stacker 3 by the second conveyor belt 223. If the weight exceeds or falls below the acceptable range, the first lifting and steering component 23 is immediately triggered to divert unqualified mattresses. It is understood that the detection data of the pressure sensor 241 is also displayed in real time on the touch screen of the control cabinet, which is convenient for operators to monitor the weight status of the mattresses in real time. At the same time, the system will also automatically record the weight data and detection time of unqualified products for subsequent quality traceability.

[0067] For example, please continue reading Figures 1-12 In this embodiment, the edge-aligning stacking machine 3 includes an edge-aligning truss 31 and a third conveyor frame 32. An edge-aligning stacking assembly 33 is provided on the edge-aligning truss 31, and a third conveyor frame 32 is provided with a third conveyor assembly 34, an edge-aligning lifting assembly 35, and an edge-aligning pushing assembly 36 for aligning the mattress to be processed.

[0068] Furthermore, the third conveying assembly 34 includes a third conveying motor 341, the output end of which is rotatably connected to a third conveying roller 342, and the third conveying roller 342 is rotatably connected to a third conveyor belt 343; thus enabling the third conveying motor 341 to drive the third conveying roller 342 to rotate, thereby driving the third conveyor belt 343 to continuously convey mattresses of acceptable weight.

[0069] Furthermore, the edge-flush stacking assembly 33 includes a third gear rack assembly 331, which is symmetrically mounted on the edge-flush truss 31. A first linear bearing assembly 333 is mounted on the top of the third gear rack assembly 331 via an edge-flush seat 332, and a second cylinder gripper assembly 335 is mounted on the bottom of the first linear bearing assembly 333 via an edge-flush frame 334.

[0070] During operation, the drive motor controls the operation of the third gear and rack assembly 331 to move the edge-aligning seat 332 and the second cylinder gripper assembly 335 horizontally, while the first linear bearing assembly 333 drives the second cylinder gripper assembly 335 to move vertically. Furthermore, a position sensor is installed at the alignment station of the third conveyor frame 32 (as prior art). Figures 1-3(Not shown in the image) The system monitors the position information of the mattress in real time and transmits it to the control system. The control system precisely controls the movement of the third gear rack assembly 331 and the first linear bearing assembly 333 based on the sensor signals, driving the second cylinder gripper assembly 335 to move above the mattress. Subsequently, the second drive cylinder drives the second gripper to close, gripping the mattress and adjusting its position according to a preset alignment reference (such as one side of the mattress as the reference), aligning the edges of the mattress to achieve automated gripping and precise alignment of the mattress to be processed.

[0071] Furthermore, the edge-aligning lifting assembly 35 includes an edge-aligning lifting frame 351, a second linear bearing assembly 353 is mounted on the top of the edge-aligning lifting frame 351 via a lifting seat 352, and edge-aligning lifting cylinders 354 are symmetrically mounted on the bottom of the edge-aligning lifting frame 351.

[0072] When the mattress is transported to the alignment station, the control system sends a command to the lifting cylinder based on the mattress thickness (indirectly fed back by the previous weighing components or detected by an additional thickness sensor). The edge alignment lifting cylinder 354 extends or retracts, pushing the edge alignment lifting frame 351 to smoothly rise and fall along the second linear bearing assembly 353, adjusting the mattress to a height that matches the edge alignment pushing component 36, preparing for subsequent edge pushing alignment. After alignment is completed, the edge alignment lifting cylinder 354 drives the edge alignment lifting frame 351 to reset, waiting for the arrival of the next mattress.

[0073] Furthermore, the edge-aligning push assembly 36 includes a second push plate 361, which is symmetrically installed on both sides of the third conveyor frame 32. The end of the edge-aligning push plate is connected to the second sliding guide rail assembly 363 through the second push frame 362. A second push cylinder 364 is installed on one side of the second sliding guide rail assembly 363.

[0074] After the edge-aligning lifting assembly 35 adjusts the mattress to the preset height, the control system sends a start signal to the second push cylinders 364 on both sides. The two push motors operate synchronously, driving the second push frame 362 to move towards each other along the second sliding guide assembly 363 via ball screws. This causes the two second push plates 361 to move towards the two sides of the mattress synchronously and apply a uniform pushing force to align the edges of the mattress. After the push is completed, the second push cylinders 364 rotate in the opposite direction, causing the second push plates 361 to reset and wait for the next alignment action.

[0075] For example, please continue reading Figures 1-12 In this embodiment, the rounded corner cutting machine 4 includes a fourth conveyor frame 41, on which a fourth conveyor assembly 42, a rounded corner cutting assembly 43 and a rounded corner limiting assembly 44 are provided for cutting the edge of the mattress.

[0076] Furthermore, the fourth conveying assembly 42 includes a fourth conveying motor 421, the output end of which is rotatably connected to the fourth conveying roller 422, and the fourth conveying roller 422 is rotatably connected to the fourth conveyor belt 423; thus, the fourth conveying motor 421 can drive the fourth conveying roller 422 to rotate, thereby driving the fourth conveyor belt 423 to continuously convey the mattress with aligned edges.

[0077] Furthermore, the rounded corner cutting assembly 43 includes a rounded corner moving frame 431. A third sliding guide rail assembly 433 is mounted on the bottom of the rounded corner moving frame 431 via a cutting seat 432. A set of fourth sliding guide rail assemblies 434 is mounted on the third sliding guide rail assembly 433. A fifth sliding guide rail assembly 435 is mounted on one side of the third sliding guide rail assembly 433.

[0078] One set of rounded corner cutting devices 438 (each cutting device is equipped with a high-speed steel saw blade, which is highly sharp and does not easily produce burrs during cutting) is symmetrically installed on both sides of the feeding end of the fourth conveyor frame 41 via the fourth sliding guide assembly 434. A first cutting motor 436 (the motor is connected to the saw blade of the cutting device via a belt) is installed on one side of the fourth sliding guide assembly 434. Correspondingly, another set of rounded corner cutting devices 438 is symmetrically installed on both sides of the discharging end of the fourth conveyor frame 41 via the fifth sliding guide assembly 435. A second cutting motor 437 (with the same structure as the first cutting motor 436 and whose power is adapted to the saw blade speed requirements) is installed on one side of the fifth sliding guide assembly 435.

[0079] During actual cutting, firstly, based on the length and width of the mattress, the control system controls the third sliding guide assembly 433 to adjust the position of the rounded corner moving frame 431 so that the cutting device is aligned with the four corners of the mattress. Then, the first cutting motor 436 drives the rounded corner cutting device 438 at the feeding end to move along the fourth sliding guide assembly 434 (perpendicular to the mattress conveying direction) to adapt to the width of the mattress, and then performs a curved movement with a preset radius (e.g., R=5cm or R=8cm) along the edges of the mattress to complete the cutting of the two corners at the feeding end of the mattress. At the same time, the second cutting motor 437 drives the rounded corner cutting device 438 at the discharging end to adjust its position along the fifth sliding guide assembly 435 (which can move perpendicular or parallel to the mattress conveying direction) to adapt to the length and width of the mattress, and then performs a curved movement along the edges of the mattress to complete the cutting of the two corners at the discharging end, ultimately realizing the automated rounded corner cutting of the four corners of the mattress.

[0080] Furthermore, the rounded corner limiting component 44 is set at the cutting station of the fourth conveyor frame 41. Its function is to firmly fix the mattress during the cutting process, prevent the mattress from shifting due to the cutting force of the saw blade, and ensure cutting accuracy. It includes four limiting plates 441 corresponding to the four corners of the mattress (installed around the cutting area of ​​the fourth conveyor frame 41, and the position can be adjusted according to the size of the mattress). Each limiting plate 441 is vertically mounted with a limiting cylinder 442 (the piston rod of the cylinder faces downward). The end of the limiting cylinder 442 is connected to the lower pressure plate 443 (the bottom of the lower pressure plate 443 is attached with an anti-slip rubber pad to increase the friction with the mattress).

[0081] Once the mattress is transported to the cutting station and positioned, the control system sends a start signal to the four limit cylinders 442. The piston rods of the limit cylinders 442 extend downwards, pushing the lower pressure plate 443 to descend synchronously until the lower pressure plate 443 presses tightly against the surface of the mattress. At the same time, the limit plates 441 on the outer side of the mattress limit the mattress from all sides, forming a fixed method of pressing from top to bottom and limiting from all sides. After the rounded corner cutting is completed, the piston rods of the limit cylinders 442 retract upwards, driving the lower pressure plate 443 to reset and release the mattress so that the mattress can be transported to the next station.

[0082] For example, please continue reading Figures 1-12 In this embodiment, the second belt conveyor 5 includes a fifth conveyor frame 51, on which a fifth conveyor assembly 52 and a second lifting and steering assembly 53 are provided for conveying the processed mattress;

[0083] The fifth conveying assembly 52 includes a fifth conveying motor 521, the output end of which is rotatably connected to a fifth conveying roller 522, and the fifth conveying roller 522 is rotatably connected to a fifth conveyor belt 523; thus, the fifth conveying motor 521 can drive the fifth conveying roller 522 to rotate, thereby driving the fifth conveyor belt 523 to continuously convey the processed mattress.

[0084] Similarly, the second lifting and steering assembly 53 includes a second lifting bogie 531, with a second lifting cylinder 532 symmetrically mounted on the bottom of the second lifting bogie 531, and a second rotating roller 533 mounted on the top of the second lifting bogie.

[0085] For example, please continue reading Figures 1-12 In this embodiment, the third belt conveyor 6 is located on one side of the collecting and stacking machine 1, the first belt conveyor 2 and / or the second belt conveyor 5. The third belt conveyor 6 includes a sixth conveying frame 61, on which a sixth conveying component 62 is provided for conveying unqualified mattresses.

[0086] Furthermore, the sixth conveying assembly 62 includes a sixth conveying motor 621, the output end of which is rotatably connected to the sixth conveying roller 622, and the sixth conveying roller 622 is rotatably connected to the sixth conveyor belt 623; thus, the sixth conveying motor 621 can drive the sixth conveying roller 622 to rotate, thereby driving the sixth conveyor belt 623 to continuously convey qualified mattresses.

[0087] It is important to explain in detail that, to ensure the coordinated operation and precise control of each processing station on the production line, each processing station has an independent control cabinet next to its corresponding machine. All control cabinets can be electrically connected to a host computer via an industrial Ethernet cable. The main interface of each control cabinet is the default display interface after the equipment is powered on. The interface design revolves around the core processing requirements of the corresponding station and is mainly used for displaying and setting parameters for the processing progress of the corresponding machine at operation stations such as product weighing, palletizing, edge trimming, and corner rounding. This includes key processing parameters such as real-time product weight, product descent time after stacking, product delivery time after stacking, minimum and maximum product weight. At the same time, the interface also displays the real-time operating status of the equipment and the action status of each component. Through this interface, operators can intuitively grasp the operating status of the equipment, quickly adjust parameters and control operations, and achieve visualized management of the processing progress of each station. The host computer can summarize, store, and analyze the parameter data of all control cabinets, facilitating production process traceability and efficiency optimization.

[0088] The present invention also provides an embodiment of an automated mattress manufacturing method, executed via the automated mattress manufacturing line as described in the above embodiments, the manufacturing method comprising:

[0089] Check the working status of the collection stacker 1, the first belt conveyor 2, the edge trimming stacker 3, the corner rounding cutter 4, the second belt conveyor 5, and the third belt conveyor 6, and confirm that each unit of the equipment is in its initial position.

[0090] Start the electrical control system to perform a self-test, import the production requirement parameter settings, and execute the automatic processing production process;

[0091] Determine the parameters of automatic palletizing, automatic weighing, and automatic cutting processes, and sort out products that do not meet the weight requirements.

[0092] For example, during specific processing and production operations:

[0093] (I) Preparations before operation:

[0094] First, check if the connections of each load-bearing frame are secure, and whether there are any cracks or deformations at the welding points. If necessary, use a wrench or other tools to check if the bolts on the frame are tightened to ensure the stability of the load-bearing frame. Next, check if the surface of the conveyor platform is flat, without any protrusions, dents, or foreign objects. If there are any foreign objects, they should be removed in time to ensure that the mattress can be placed stably on the platform. Then, check if the connection line of the pressure sensor 241 is secure, without any damage or aging, and ensure that the connection between the sensor and the load-bearing frame is tight. Then, test the operation of the inlet and outlet conveyor rollers. After starting the rollers, observe whether their rotation is smooth, without any jamming or abnormal noise, and whether the surface of the rollers is smooth, without any scratches or deformation. Finally, check the control panel and display screen of the control system. Turn on the power and check if the display screen displays normally, whether the touch buttons are sensitive, and whether each function button can be operated normally.

[0095] Simultaneously check whether the pneumatic push rod and diversion baffle move flexibly, whether the extension and retraction of the pneumatic push rod are smooth, and whether the rotation of the diversion baffle is in place and without any jamming. Then check whether the grippers of the palletizing device are intact, and whether the rubber anti-slip pads of the grippers are worn or detached. If they are severely worn, they need to be replaced in time to ensure that the grippers can firmly grasp the mattress. Next, check whether the position of the push plate is appropriate. According to the specifications of the mattress to be processed, check whether the front and rear positions of the push plate need to be adjusted, and whether the connection of the corresponding drive motor or pneumatic solenoid valve is secure. Then start the motor and observe whether its rotation is smooth, whether there are any abnormal noises or overheating, and whether the motor connection lines are secure and whether they are loose or aged. Then check whether the operation of the limit mechanism of the palletizing device is smooth, and confirm whether the lubrication of the ball screw and guide rail is good. Check whether the pressing and positioning components move flexibly, whether the cylinder extension and retraction are smooth, whether the buffer pad is worn, whether the position of the positioning baffle is accurate, and whether the adjustment is flexible.

[0096] Check if the motor of the cutting device is normal. Start the motor and observe whether its rotation is smooth, whether there are any abnormal noises or overheating. Check if the motor connection is secure and whether it is loose or aged. Check the sharpness of the cutting blades and observe whether there is any wear or nicks on the blade surface. If so, grind or replace them in time to ensure the cutting effect. Check whether the movement of the cylinder slide rail is smooth and whether there is any jamming or abnormal noise. Check whether the slide rail surface is smooth and whether there are any scratches or deformations. Test the function of automatic sanding of the blades. Set the sanding program through the IO panel and observe whether the sanding device can automatically approach the blade and perform sanding. Check whether the sanding process is smooth. Check whether the cylinder of the rounded corner limit component 44 moves flexibly, whether the rubber pad of the lower pressure plate 443 is worn, whether the cylinder connection is secure, and check whether the position of the positioning baffle is accurate and flexible in adjustment. Check whether the surface of the baffle is deformed.

[0097] (II) Processing and Production Process

[0098] Start-up Phase: Through systematic initialization, ensure that all functional units meet the processing conditions, confirm that all equipment units, such as the automatic weighing unit, automatic palletizing unit, and automatic corner rounding unit, are in their initial positions (e.g., grippers reset, platform lowered to the lowest position, conveyor belt stopped). Simultaneously, clear the area around the equipment to ensure no unauthorized personnel are present. Connect the main power supply and press the power button. The control system (including PLC and touchscreen) is powered on and starts. The touchscreen loads the preset operating program, completing the initial activation of the electrical system. At this point, the interface enters a self-test state. The control system will check the connection integrity and movement flexibility of each unit's core components (e.g., weighing sensor wiring, palletizing drive motor, cutter motor, pneumatic components). If a fault is detected (e.g., loose sensor, abnormal motor noise), the system will display a fault code and alarm on the touchscreen. Operators must troubleshoot and repair the fault before re-checking. Only equipment that passes the self-test is ready to enter the processing stage. This step can eliminate potential faults in advance and avoid processing interruptions.

[0099] Setup Phase: After self-inspection, key processing parameters are set on the touchscreen according to production order requirements: the weighing unit sets the minimum / maximum weight of the product to define the acceptable weight range; the palletizing unit sets the number of palletizing layers, the product descent time after stacking, and the product delivery time after stacking to control the stacking rhythm; the corner rounding unit sets the corner radius, cutting speed, etc., to determine the processing size and efficiency. All parameters must be checked to ensure they are consistent with product standards. Click the automatic run button on the touchscreen, and the control system sends a start command to each unit. The drive motors, pneumatic components, etc., simultaneously enter the standby state, and the equipment completes the start-up preparation and enters the automatic operation mode.

[0100] Operational Phase: After the mattress to be processed is fed in by the product inlet roller conveyor, it is smoothly transported to the weighing platform. The weighing sensor on the weighing platform senses the weight of the mattress in real time and converts the weight signal into an electrical signal, which is transmitted to the PLC control system. The control system compares the real-time weight with the preset minimum / maximum weight for product compliance. If the weight is within the acceptable range, the mattress is transported to the automatic palletizing unit. If the weight exceeds the limit, the unqualified mattress is diverted to the unqualified product outlet channel, and the system triggers an alarm to prompt the operator to handle the situation and prevent unqualified products from entering subsequent processes.

[0101] After a qualified mattress enters the palletizing area, a proximity switch detects its arrival and sends a signal to the control system. The drive motor 3 controls the grippers of the palletizing device to automatically pick up the mattress. Then, the drive motor 1 controls the lifting platform to descend to the appropriate height, and the grippers place the mattress on the platform. After placement, the mattresses are automatically aligned to prevent stacking misalignment. As the number of mattresses stacked increases, the lifting platform descends synchronously according to the mattress thickness until the preset number of stacking layers is reached. Finally, the entire stack of mattresses is transported to the automatic rounded corner unit.

[0102] After the entire stack of mattresses is conveyed to the fixed and movable platforms of the rounded corner unit, the spacing is adjusted according to the preset mattress size to ensure that the mattresses fit the positioning baffles. Then, the clamping device firmly fixes the mattresses to prevent them from shifting during cutting. After fixing, the cutter motor drives the cutting device to start the cutting action according to the preset rounded corner radius, making curved cuts on the four corners of the mattresses. After cutting, the automatic sanding device approaches the saw blade according to the preset program to sharpen the saw blade to ensure the sharpness of subsequent cuts. After all processing is completed, the processed mattresses are sent out to enter the finished product conveying stage.

[0103] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An automated mattress manufacturing production line, characterized in that, include: A stacking machine includes a stacking truss and a first conveyor frame. The stacking truss is equipped with a stacking collection component, and the first conveyor frame is equipped with a first conveying component and a stacking pushing component for collecting and stacking mattresses to be processed. The first belt conveyor includes a second conveyor frame, on which a second conveyor assembly, a first lifting and steering assembly, and a conveying and weighing assembly are provided for diverting mattresses that do not meet the weight requirements. The edge-aligning stacking machine includes an edge-aligning truss and a third conveyor frame. The edge-aligning truss is equipped with an edge-aligning stacking component, and the third conveyor frame is equipped with a third conveying component, an edge-aligning lifting component, and an edge-aligning pushing component for aligning mattresses to be processed. A corner rounding cutter includes a fourth conveyor frame, on which a fourth conveyor assembly, a corner rounding cutter assembly, and a corner rounding limit assembly are provided for cutting the edges of a mattress; The second belt conveyor includes a fifth conveyor frame, on which a fifth conveyor assembly and a second lifting and steering assembly are provided for conveying the processed mattress; The mattresses to be processed are sequentially stacked, sorted, processed, and transported through a collection and stacking machine, a first belt conveyor, an edge-trimming stacking machine, a corner-rounding cutter, and a second belt conveyor.

2. The production line according to claim 1, characterized in that, The first conveying assembly includes a first conveying motor, the output end of which is rotatably connected to a first conveying roller, and the first conveying roller is rotatably connected to a first conveyor belt; The collection and stacking assembly includes a first gear and rack assembly, which is symmetrically mounted on the stacking truss. A second gear and rack assembly is mounted on the top of the first gear and rack assembly via a sliding seat, and a first cylinder gripper assembly is mounted on the bottom of the second gear and rack assembly via a clamping frame. The collection and pushing component includes a first pushing plate, the end of which is connected to a first sliding guide rail assembly via a first pushing frame, and a first pushing motor is installed on one side of the first sliding guide rail assembly.

3. The production line according to claim 1, characterized in that, The second conveying assembly includes a second conveying motor, the output end of which is rotatably connected to a second conveying roller, and the second conveying roller is rotatably connected to a second conveyor belt; The first lifting and steering assembly includes a first lifting bogie, a first lifting cylinder symmetrically mounted on the bottom of the first lifting bogie, a first rotating roller mounted on the top of the first lifting bogie, a first steering motor mounted inside the first lifting bogie, and the first steering motor rotatably connected to the first rotating roller. The conveying and weighing assembly includes a pressure sensor, which is symmetrically installed at the bottom of the second conveyor frame.

4. The production line according to claim 1, characterized in that, The third conveying assembly includes a third conveying motor, the output end of which is rotatably connected to a third conveying roller, and the third conveying roller is rotatably connected to a third conveyor belt; The edge-aligning stacking assembly includes a third gear rack assembly, which is symmetrically mounted on the edge-aligning truss. A first linear bearing assembly is mounted on the top of the third gear rack assembly via an edge-aligning seat, and a second cylinder gripper assembly is mounted on the bottom of the first linear bearing assembly via an edge-aligning frame.

5. The production line according to claim 1, characterized in that, The edge-aligning lifting assembly includes an edge-aligning lifting frame, a second linear bearing assembly is mounted on the top of the edge-aligning lifting frame via a lifting seat, and edge-aligning lifting cylinders are symmetrically mounted on the bottom of the edge-aligning lifting frame. The edge-aligning push assembly includes a second push plate, which is symmetrically installed on both sides of the third conveyor frame. The end of the edge-aligning push plate is connected to the second sliding guide rail assembly through the second push frame. A second push cylinder is installed on one side of the second sliding guide rail assembly.

6. The production line according to claim 1, characterized in that, The fourth conveying assembly includes a fourth conveying motor, the output end of which is rotatably connected to a fourth conveying roller, and the fourth conveying roller is rotatably connected to a fourth conveyor belt; The rounded corner cutting assembly includes a rounded corner moving frame. A third sliding guide rail assembly is mounted on the bottom of the rounded corner moving frame via a cutting seat. A set of fourth sliding guide rail assemblies is mounted on the third sliding guide rail assembly, and a fifth sliding guide rail assembly is mounted on one side of the third sliding guide rail assembly.

7. The production line according to claim 1, characterized in that, A set of rounded corner cutting devices are symmetrically installed on both sides of the feed end of the fourth conveyor frame via a fourth sliding guide assembly. A first cutting motor is installed on one side of the fourth sliding guide assembly. A set of rounded corner cutting devices are symmetrically installed on both sides of the discharge end of the fourth conveyor frame via a fifth sliding guide assembly. A second cutting motor is installed on one side of the fifth sliding guide assembly. The rounded corner limiting assembly includes a limiting plate, a limiting cylinder is installed above the limiting plate, and a pressure plate is installed at the end of the limiting cylinder.

8. The production line according to claim 1, characterized in that, The fifth conveying assembly includes a fifth conveying motor, the output end of which is rotatably connected to a fifth conveying roller, and the fifth conveying roller is rotatably connected to a fifth conveyor belt; The second lifting and steering assembly includes a second lifting bogie, with a second lifting cylinder symmetrically mounted on the bottom of the second lifting bogie and a second rotating roller mounted on the top of the second lifting bogie.

9. The production line according to claim 1, characterized in that, It also includes a third belt conveyor, which is located on one side of the collecting stacker and / or the first belt conveyor. The third belt conveyor includes a sixth conveyor frame, on which a sixth conveyor assembly is provided for conveying non-conforming mattresses. The sixth conveying assembly includes a sixth conveying motor, the output end of which is rotatably connected to a sixth conveying roller, and the sixth conveying roller is rotatably connected to a sixth conveyor belt.

10. An automated mattress manufacturing method, characterized in that, The production method is performed via an automated mattress production line as described in any one of claims 1 to 9, the production method comprising: Check the working status of the stacker, first belt conveyor, edge trimming stacker, corner rounding cutter, second belt conveyor, and third belt conveyor, and confirm that each unit of the equipment is in its initial position; Start the electrical control system to perform a self-test, import the production requirement parameter settings, and execute the automatic processing production process; Determine the parameters of automatic palletizing, automatic weighing, and automatic cutting processes, and sort out products that do not meet the weight requirements.

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