A smart mattress production line

Abstract

This invention discloses an intelligent mattress production line, belonging to the field of intelligent manufacturing equipment. The invention includes a foam board gluing station equipped with a robotic arm and a foam board clamp. The foam board clamp comprises a clamp base, a layered material handling module, and an edge adjustment mechanism. Monitoring cameras are installed at the four corners of the clamp base, and negative pressure suction cups are arranged at the bottom. The layered material handling module is equipped with two sets of material handling plates and pressure plates, relying on cylinder drive to complete the layering of inserts and the pressure limiting. The edge adjustment mechanism uses a servo screw to drive the adjustment plate, adapting to foam boards of different sizes. This invention solves the problem of multi-layer gripping caused by static electricity and the soft, sticky texture of the foam boards by staggered lifting and separating the stacked foam boards through the double material handling plates, achieving non-destructive picking of single sheets. Visual monitoring ensures the accuracy of material handling alignment, and the negative pressure suction cups improve the stability of transport. It eliminates the need to puncture the foam board, protecting the foam structure of the board, reducing downtime and material loss, and is suitable for intelligent continuous production of mattresses throughout the entire process.

Description

Technical Field

[0001] This invention relates to the field of intelligent manufacturing equipment, specifically to an intelligent production line for mattresses. Background Technology

[0002] With the intelligent upgrading of the furniture manufacturing industry, intelligent mattress production lines have gradually replaced traditional manual assembly lines. Relying on robotic arms, visual inspection, and automated gripping equipment, they achieve unmanned operation throughout the entire process of board feeding, gluing, and bonding, effectively improving mattress processing precision and production cycle time. This is a core supporting equipment for modern mattress manufacturing. In the automated mattress production process, robotic arms grip stacked foam boards and complete the glue spraying and bonding process. The mechanized gripping structure significantly reduces manual labor intensity and improves the automation level of the production line. Invention patent CN112589779B provides a robotic arm for gripping and laying in mattress production. This design features a movable, flat support frame with multiple cross-arranged insertion pins around the frame. These pins penetrate the foam to create clamping force, thereby completing the gripping, transfer, and laying of the foam boards.

[0003] This piercing gripping structure has the following obvious defects in actual production: First, the stacked sponge sheets are soft and tightly bonded. Furthermore, static electricity easily causes them to adhere to each other during production and transport. When the insertion needle pierces downwards as a whole, it cannot separate the layers, and the piercing action directly penetrates multiple layers of sponge. This makes it easy to pick up multiple sheets of sponge at once, especially for thinner sheets where the layer separation is even lower, leading to frequent multi-layer picking failures. Once multiple sheets of sponge are picked up simultaneously, the machine must be stopped and the sheets manually separated, disrupting the continuous operation of the production line and reducing production efficiency.

[0004] Secondly, this method relies on hard insertion needles to pierce the sponge to achieve clamping. The piercing operation will create a large number of needle holes inside the sponge, destroying the foam structure of the sponge, causing local collapse and damage to the sponge, which will greatly reduce the sponge's resilience and impair the long-term quality of the mattress.

[0005] Therefore, the industry urgently needs a gripping device that can accurately pick up individual sheets of sponge in layers without damaging the board material. Summary of the Invention

[0006] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: This invention provides an intelligent mattress production line, including a foam board gluing station equipped with a robotic arm and a foam board clamp. The foam board clamp comprises a clamp base and several layered material handling modules. The clamp base is a rectangular frame structure, with its top center connected to the end effector of the robotic arm. The robotic arm drives the entire clamp to complete spatial movement and alignment operations. Monitoring cameras are installed at each of the four corners of the clamp base, facing inwards to collect real-time images of the foam board position, material handling gaps, and gluing alignment, enabling visual positioning and process monitoring. The layered material handling modules are installed around the clamp base and consist of a lifting cylinder, a lifting guide shaft, a transverse insertion cylinder, and a material handling plate. The lifting cylinder body is fixed to the outer wall of the clamp base, and its piston rod is connected to the transverse insertion cylinder, allowing it to move vertically up and down. One end of the lifting guide shaft is fixedly installed on the outer wall of the transverse insertion cylinder. The lifting guide shaft body is slidably assembled with the fixture base. When the lifting cylinder extends or retracts, it drives the transverse insertion cylinder and the lifting guide shaft to slide synchronously in the vertical direction. The lifting guide shaft constrains the lifting trajectory of the transverse insertion cylinder, preventing swaying during the lifting process. A picking plate is installed at the extension end of the transverse insertion cylinder. The horizontal insertion and removal of the picking plate is achieved by the extension and retraction of the transverse insertion cylinder. The picking plate is arranged on the outer side of the bottom of the fixture base, and extends towards the inner side of the fixture base, so that it can be inserted into the gap between the stacked sponge boards to complete the lifting and picking of the boards. The end of the picking plate that extends into the inner side of the fixture base has a beveled chamfer. The chamfer makes the thickness of the picking plate gradually narrow, so that it can smoothly wedge into the gap between the multi-layer sponge boards during the insertion operation, reducing the squeezing and scratching damage to the sponge during insertion and improving the smoothness of layered material picking.

[0007] The foam board clamp is also equipped with an edge adjustment mechanism, which includes adjustment plates, guide rods, and an adjustment drive structure. There are four adjustment plates, each corresponding to one of the four outer sides of the clamp base. Each of the four sides of the clamp base is equipped with a guide rod and an adjustment drive structure. The guide rods penetrate the sidewalls of the clamp base and slide against it, providing guidance and limiting for the translational movement of the adjustment plates. The outer ends of the guide rods are fixedly connected to the adjustment plates on the same side. The adjustment drive structure drives the corresponding adjustment plate to translate along the guide rods, thus adapting to the clamping range of foam boards from mattresses of different sizes and specifications. The cylinder body of the lifting cylinder is fixedly mounted on the adjustment plate and adjusts its installation position synchronously with the adjustment plate.

[0008] The adjustment drive structure includes a servo motor, a lead screw, a nut sleeve, and an anti-rotation guide rod. The output shaft of the servo motor is connected to the lead screw drive, converting rotational power into linear driving force. The nut sleeve is threaded onto the outside of the lead screw, achieving linear displacement as the lead screw rotates. The anti-rotation guide rod is arranged parallel to the lead screw and is slidably embedded on the outside of the nut sleeve, restricting circumferential rotation of the nut sleeve and ensuring that the nut sleeve can only move linearly. The nut sleeve extends outward to form a connecting tube, which is used to fix the nut sleeve to the adjustment plate, transmitting the linear driving force to the adjustment plate to accurately complete the clamp width adjustment.

[0009] As a preferred option, multiple sets of negative pressure suction cups are installed on the clamp base, with the negative pressure suction cups facing downwards on the bottom surface of the clamp base. All the negative pressure suction cups are connected to an external negative pressure air source that can be turned on and off. The negative pressure adsorption method is used to assist in fixing the middle of the sponge board, thereby improving the stability of the board during the transfer process.

[0010] Furthermore, the lifting cylinder, the transverse insertion cylinder, and the picking plate in the layered picking module are all set in two sets. The three are paired and installed side by side. The two sets of picking plates can work together to complete the staggered picking action, separate the sponge boards that are stuck together, and avoid picking up multiple layers of boards at once.

[0011] Furthermore, the layered material handling module is further equipped with a second lifting cylinder, a second lifting guide shaft, a transverse cylinder, and a pressure plate. The second lifting cylinder has the same structure as the lifting cylinder, the transverse cylinder and the transverse insertion cylinder have the same structure, and the initial structure of the pressure plate is the same as the material handling plate. The output end of the second lifting cylinder is connected to the transverse cylinder, one end of the second lifting guide shaft is fixed to the outer wall of the transverse cylinder, and the shaft of the second lifting guide shaft is slidably assembled with the fixture base. When the second lifting cylinder extends or retracts, it drives the transverse cylinder and the second lifting guide shaft to slide vertically synchronously. The second lifting guide shaft limits the lifting path of the transverse cylinder to prevent shaking or deviation. The extension end of the transverse cylinder is fixed with the pressure plate, which is arranged facing the inside of the fixture base. The second lifting cylinder, the transverse cylinder, and the pressure plate are assembled in the middle area of ​​the two sets of lifting cylinders. During the material handling process, the pressure plate can extend downwards to work with the material handling plates on both sides to clamp the sponge board and prevent the board from tilting or shifting.

[0012] Furthermore, the width of the pressure plate is larger than that of the take-up plate, and raised anti-slip textures are provided on the bottom surface of the pressure plate to increase the friction between the pressure plate and the sponge plate, making it less likely to slip during clamping and improving clamping reliability.

[0013] This invention also provides an automated bonding process for foam boards based on the aforementioned intelligent mattress production line. Corresponding to the negative pressure suction cup solution workflow, a robotic arm drives a foam board clamp to complete the clamping, transfer, and bonding of stacked foam boards. The specific steps are as follows: Step 1: The robotic arm drives the gripper base to move horizontally to a position above the top layer of the stacked sponge boards; Step 2: The lifting cylinder descends, causing the material picking plate to align with the gap between the top layer sponge board and the second-to-last layer sponge board; Step 3: Extend the horizontal insertion cylinder to insert the material picking plate into the gap between the two layers of sponge board. Simultaneously activate the negative pressure suction cup to adsorb and fix the sponge board from the middle position. Step 4: The lifting cylinder lifts upwards, completely detaching the top layer of sponge board from the lower board. Step 5: The robotic arm carries the sponge board fixture and the sponge board to the adhesive station and completes the positioning. Step 6: The horizontal insertion cylinder retracts, the material pick-up plate is removed from the bottom of the sponge board, the sponge board falls naturally, the clamp base applies downward pressure to press the sponge board tightly against the surface of the mattress body, and finally the negative pressure suction cup is closed to release the adsorption, completing the sponge board bonding operation.

[0014] This invention also provides an automated bonding process for foam boards based on the aforementioned intelligent mattress production line. Corresponding to the staggered material handling scheme of the double-board picking method, a robotic arm drives a foam board clamp to complete the clamping, transfer, and bonding of stacked foam boards. The specific steps are as follows: Step 1: The robotic arm drives the gripper base to move horizontally to a position above the top layer of the stacked sponge boards; Step 2: The lifting cylinder descends, causing the material picking plate to align with the gap between the top layer sponge board and the second-to-last layer sponge board; Step 3: The transverse insertion cylinder extends and inserts the material pick-up plate into the gap between the two layers of sponge board; the two sets of material pick-up plates adopt a staggered action mode, with one side of the material pick-up plate supporting the top layer of sponge board and the other side of the material pick-up plate pressing down on the second-to-top layer of sponge board to prevent the multiple layers of sponge board from sticking together and being pulled up. Step 4: After one side of the lifting cylinder slightly lifts the sponge board, the other side of the material picking plate switches to the lifting mode, and together they lift the top sponge board completely. Step 5: The robotic arm carries the sponge board fixture and the sponge board to the adhesive station and completes the positioning. Step Six: The transverse insertion cylinder retracts, the material removal plate is removed from the bottom of the sponge board, the sponge board falls naturally, and the robotic arm drives the clamp base to press down the sponge board as a whole, so that the sponge board is tightly bonded to the mattress body.

[0015] This invention also provides an automated bonding process for foam boards based on the aforementioned intelligent mattress production line. A corresponding pressure plate solution is added to the workflow, where a robotic arm drives a foam board clamp to complete the clamping, transfer, and bonding of stacked foam boards. The specific steps are as follows: Step 1: The robotic arm drives the gripper base to move horizontally to a position above the top layer of the stacked sponge boards; Step 2: The lifting cylinder descends, causing the material picking plate to align with the gap between the top layer sponge board and the second-to-last layer sponge board; Step 3: The horizontal insertion cylinder extends and inserts the material picker into the gap between the two layers of sponge board; the two sets of material picker adopt a staggered action mode, with one side of the material picker lifting the top layer of sponge board and the other side of the material picker pressing down on the sponge board to prevent the multiple layers of sponge board from sticking together and being pulled up. Step 4: After one side of the lifting cylinder slightly lifts the sponge board, the other side of the material picking plate switches to the lifting mode, and at the same time, the pressure plate extends downward to clamp the sponge board and completely lift the top sponge board. Step 5: The robotic arm carries the sponge board fixture and the sponge board to the adhesive station and completes the positioning. Step Six: The transverse insertion cylinder retracts, the material pick-up plate is removed from the bottom of the sponge board, the sponge board falls and adheres to the mattress body, and the robotic arm drives the clamp base to press down the sponge board as a whole, completing the sponge board bonding operation.

[0016] The beneficial effects of this invention are as follows: 1. This invention features a layered material picking module. A lifting cylinder drives a horizontal insertion cylinder to vertically lift and align the material. The horizontal insertion cylinder then drives a picking plate to horizontally insert into the gaps between stacked sponge boards. This mechanical layered insertion method enables the picking of individual sponge boards layer by layer, accurately separating mutually adhered sponge boards and eliminating the problem of multiple sponge boards being picked up together. The picking action is stable and reliable, ensuring continuous and stable operation of the production line and significantly reducing material waste and downtime.

[0017] 2. The present invention sets two sets of parallel material picking structures in the layered material picking module. The two sets of material picking plates can perform staggered material picking actions, which can separate the sticky sponge boards and eliminate the failure problem of grabbing multiple layers of sponge boards at one time.

[0018] 3. The present invention arranges monitoring cameras facing inward at the four corners of the fixture base, which can collect material position and bonding alignment images in real time, realize visual precision positioning, and improve the alignment accuracy of sponge board picking and bonding.

[0019] 4. The present invention is equipped with an edge adjustment mechanism, which uses a servo motor lead screw to drive the adjustment plate to move along the guide rod, so as to flexibly adjust the overall clamping size of the clamp and adapt to mattress foam boards of different specifications and sizes, thus making it more versatile.

[0020] 5. The present invention features a drive structure with an anti-rotation guide rod and a lead screw nut sleeve, which can limit the circumferential rotation of the nut sleeve, stabilize the motor rotation into linear displacement, and achieve high control precision in size adjustment and smooth operation.

[0021] 6. The present invention adds a negative pressure suction cup to the bottom of the clamp base, which uses a negative pressure air source to adsorb the middle part of the sponge board, forming an auxiliary fixation during the transfer process, preventing the sponge board from shifting or falling, and improving the stability of the conveying process.

[0022] 7. The present invention adds a pressure plate structure between the two sets of material picking modules. When picking up materials, it can work with the material picking plates on both sides to clamp and limit the sponge board, preventing the sponge board from tilting and deviating, and making the material lifting process more stable.

[0023] 8. The present invention sets the pressure plate to be wider than the material taking plate and sets raised anti-slip texture on the bottom surface, which increases the contact area and contact surface friction with the sponge board, making it less prone to slipping during clamping and significantly improving the clamping firmness.

[0024] 9. This invention adopts a structure in which a robotic arm carries a sponge board clamp. The robotic arm drives the clamp to complete all-dimensional spatial movement, which can flexibly complete the gripping, transfer and bonding of sponge boards to the workstation. It has a high degree of automation and saves manual operation.

[0025] 10. In the process flow of this invention, the two sets of material picking plates adopt a staggered action mode, and lift the board layer by layer through the cooperation of one lifting and one pressing, so as to stably realize the peeling and picking of a single sponge board, effectively avoiding the situation where multiple sponge boards are stuck together and are lifted up at the same time, reducing the probability of production failure. Attached Figure Description

[0026] Figure 1 This is a schematic diagram showing the connection relationship and three-dimensional structure of the robotic arm and the sponge plate clamp.

[0027] Figure 2 This is a schematic diagram of the three-dimensional structure of the sponge board clamp.

[0028] Figure 3 This is a three-dimensional structural diagram of the sponge board clamp from another angle.

[0029] Figure 4 for Figure 3 Enlarged view of point A in the image.

[0030] Figure 5 This is a three-dimensional structural diagram of the layered material handling module in Example 1.

[0031] Figure 6 A schematic diagram of the internal three-dimensional structure of the adjustment drive mechanism.

[0032] Figure 7 This is a three-dimensional structural diagram of the layered material handling module in Example 2.

[0033] Figure 8 This is a three-dimensional structural diagram of the layered material handling module in Embodiment 3.

[0034] In the diagram: 1. Robotic arm; 2. Sponge board clamp; 21. Clamp base; 22. Layered material handling module; 221. Lifting cylinder; 222. Lateral insertion cylinder; 223. Material handling plate; 224. Anti-slip texture; 225. Second lifting cylinder; 226. Lateral cylinder; 227. Pressure plate; 228. Lifting guide shaft; 229. Second lifting guide shaft; 23. Edge adjustment mechanism; 231. Adjustment plate; 232. Guide rod; 2321. Limiting structure; 233. Adjustment drive structure; 2331. Servo motor; 2332. Lead screw; 2333. Nut sleeve; 2334. Anti-rotation guide rod; 2335. Connecting pipe; 24. Negative pressure suction cup; 25. Monitoring camera. Detailed Implementation Example 1

[0035] like Figure 1-6As shown, a smart mattress production line includes a foam board bonding station equipped with a robotic arm 1 and a foam board clamp 2. The robotic arm 1 can drive the foam board clamp 2 to achieve multi-dimensional spatial movement, completing the foam board gripping, transfer, and bonding operations. The foam board clamp 2 includes a clamp base 21 with a rectangular mesh frame structure and a multi-component layered material handling module 22. The rectangular mesh frame clamp base 21 is lightweight and can evenly support the negative pressure adsorption and layered material handling components. The end of the robotic arm 1 is fixed to the top center of the clamp base 21. Monitoring cameras 25 facing inward are installed at the four corners of the clamp base 21, which can collect images of the foam board stacking position, interlayer gaps, and bonding alignment without blind spots, realizing visual positioning and full-process operation monitoring. Each layered material handling module 22 is equipped with two sets of parallel-arranged lifting cylinders 221, lifting guide shafts 228, transverse insertion cylinders 222, and a material handling plate 223; the cylinder body of the lifting cylinder 221 is fixed to the adjusting plate 231, the piston rod of the lifting cylinder 221 is connected to the transverse insertion cylinder 222, one end of the lifting guide shaft 228 is fixedly mounted on the outer wall of the transverse insertion cylinder 222, and the rod body of the lifting guide shaft 228 is slidably engaged with the clamp base 21. When the transverse inserting cylinder 222 is driven to move vertically up and down, the lifting guide shaft 228 slides synchronously along the clamp base 21 to constrain the lifting trajectory of the transverse inserting cylinder 222 and prevent swaying during the lifting process. The telescopic end of the transverse inserting cylinder 222 is equipped with a picking plate 223, which extends into the clamp base 21. The inner end of the picking plate 223 has a chamfered edge and the end thickness gradually narrows, which can smoothly wedge into the gap between the layers of the sponge board and reduce the scratch damage of the inserting material. A second lifting cylinder 225, a second lifting guide shaft 229, a transverse cylinder 226, and a pressure plate 227 are installed in the middle of the two sets of lifting cylinders 221. The piston rod of the second lifting cylinder 225 is connected to the transverse cylinder 226. One end of the second lifting guide shaft 229 is fixed to the outer wall of the transverse cylinder 226. The rod body of the second lifting guide shaft 229 is slidably assembled with the clamp base 21. When the second lifting cylinder 225 drives the transverse cylinder 226 to rise and fall, the second lifting guide shaft 229 slides and limits synchronously to prevent the transverse cylinder 226 from deviating during rise and fall. The size of the pressure plate 227 is consistent with that of the picking plate 223. The uniform specification of the board material can reduce the cost of spare parts storage. During operation, the pressure plate 227 presses down and cooperates with the lifting of the picking plates 227 on both sides to clamp the sponge board, restrict the vertical displacement of the board material, and prevent the sponge board from warping during transportation. Multiple sets of downward-facing negative pressure suction cups 24 are installed on the bottom surface of the clamp base 21. The negative pressure suction cups 24 are connected to a controllable negative pressure air source. The negative pressure suction cups 24 are adsorbed and fixed from the middle of the sponge board, providing central support during the transfer process to prevent the middle of the thin plate from collapsing.The sponge board clamp 2 is also equipped with an edge adjustment mechanism 23. Four adjustment plates 231 are arranged on the four outer sides of the clamp base 21. The adjustment drive structure 233, composed of a servo motor 2331, a lead screw 2332, a nut sleeve 2333, and an anti-rotation guide rod 2334, drives the adjustment plates 231 to move along the guide rod 232. The servo lead screw drive method has high adjustment accuracy and can adapt to sponge boards of different lengths and widths. A limit structure 2321 is set at the inner end of the guide rod 232. The limit structure 2321 limits the maximum movement stroke of the adjustment plate to prevent overtravel and impact on the components. The lifting cylinder 221 is fixed on the adjustment plate 231. The layered material picking module moves synchronously with the adjustment plate and adapts to the size of the board. The robotic arm 1, monitoring camera 25, lifting cylinder 221, transverse insertion cylinder 222, second lifting cylinder 225, transverse cylinder 226, servo motor 2331, and negative pressure system of negative pressure suction cup 24 are all externally connected to a numerical control system. The timing of each component's action, travel distance, and start / stop status are all automatically and uniformly controlled by the numerical control system.

[0036] The sponge board clamping and bonding process in this embodiment is as follows: The robotic arm 1 drives the gripper base 21 to move horizontally above the top layer of the stacked sponge boards. The four corner monitoring cameras 25 collect images of the board position in real time to complete visual positioning. The lifting cylinder 221 moves downward to align the picking plate 223 with the gap between the top and second-to-top sponge boards. The lateral insertion cylinder 222 extends outward, and the picking plate 223 inserts into the gap between the two layers of sponge boards. The two sets of picking plates 223 move in a staggered manner, one side lifting the top sponge board and the other side pressing the board to separate the adhesive parts. At the same time, the negative pressure suction cup 24 is activated to adsorb the middle position of the sponge board. The second lifting cylinder 225 drives the lateral movement. Cylinder 226 extends, pressing plate 227 presses down to adhere to the side of the sponge board, one side lifting cylinder 221 slightly lifts the board, and the two side picking plates 223 switch to a joint lifting state, completely lifting the single sponge board away from the stacked boards below. Robotic arm 1 carries sponge board clamp 2 and sponge board to the top of the adhesive station to complete the alignment. Lateral insertion cylinder 222 retracts, picking plate 223 withdraws from the bottom of the sponge board, and robotic arm 1 drives clamp base 21 to apply downward pressure to make the sponge board tightly adhere to the mattress body. Finally, the negative pressure air source is cut off to release the adsorption effect of negative pressure suction cup 24, and the entire sponge board bonding operation is completed. Example 2

[0037] The overall structure of this embodiment is basically the same as that of Embodiment 1, except that the width of the pressure plate 227 is greater than that of the take-up plate 223, the bottom surface of the pressure plate 227 is provided with raised anti-slip texture 224, and all the negative pressure suction cups 24 and the matching controllable negative pressure air source at the bottom of the clamp base 21 are removed. Figure 7 As shown.

[0038] The sponge board clamping and bonding process in this embodiment is as follows: The robotic arm 1 drives the gripper base 21 to move horizontally above the top layer of the stacked sponge boards. Four corner monitoring cameras 25 capture real-time images of the board's position for visual positioning. The lifting cylinder 221 moves downwards, aligning the picking plate 223 with the gap between the top and second-to-top sponge boards. The transverse insertion cylinder 222 extends outwards, inserting the picking plate 223 into the gap between the two layers of sponge boards. The two sets of picking plates 223 operate in a staggered manner, one side supporting the top sponge board, the other side pressing down on the boards to separate the adhesive areas. The second lifting cylinder 225 drives the transverse cylinder 226 to extend, widening the pressure plate with anti-slip texture on the bottom. 227 Press down on the side of the sponge board, relying on the increased contact area and anti-slip texture to clamp the board. After the lifting cylinder 221 on one side slightly lifts the board, the material picking plates 223 on both sides switch to the joint lifting state, lifting the single sponge board completely away from the stacked boards below. The robotic arm 1 carries the sponge board clamp 2 and the sponge board to the top of the adhesive station to complete the alignment. The transverse insertion cylinder 222 retracts, and the material picking plate 223 is removed from the bottom of the sponge board. The sponge board falls naturally onto the surface of the mattress body. The robotic arm 1 drives the clamp base 21 to apply downward pressure to make the sponge board tightly adhere to the mattress body. The entire sponge board bonding operation is completed.

[0039] Compared to Embodiment 1, this embodiment removes the entire suction structure of the negative pressure suction cup, resulting in a lighter fixture, lower load on the robotic arm, faster operation, and reduced investment and daily maintenance costs for negative pressure equipment. The widened pressure plate with anti-slip texture can improve the side clamping friction, compensating for the lack of limiting force caused by the absence of negative pressure suction. However, the lack of central negative pressure support makes the middle of the board prone to collapse when processing thin, large-sized sponge boards, resulting in insufficient clamping stability. It is more suitable for processing sponge boards with higher thickness, smaller size, and better rigidity. Example 3

[0040] The overall structure of this embodiment is basically the same as that of Embodiment 1. The difference is that the entire set of pressing-related components, including the second lifting cylinder 225, the transverse cylinder 226, and the pressing plate 227, is removed. Figure 8 As shown.

[0041] The sponge board clamping and bonding process in this embodiment is as follows: The robotic arm 1 drives the clamp base 21 to move horizontally above the top layer of stacked sponge boards. The four corner monitoring cameras 25 collect the board position images in real time to complete visual positioning. The lifting cylinder 221 moves downward to align the picking plate 223 with the gap between the top and second-to-top sponge boards. The transverse insertion cylinder 222 extends outward, and the picking plate 223 is inserted into the gap between the two layers of sponge boards. The two sets of picking plates 223 move in a staggered manner, with one side supporting the top sponge board and the other side pressing the board to separate the bonding parts. The negative pressure is activated simultaneously. The suction cup 24 adsorbs the middle of the sponge board. A lifting cylinder 221 on one side slightly lifts the board, and the two lifting plates 223 switch to a joint lifting state, completely lifting the single sponge board away from the stacked boards below. The robotic arm 1, carrying the sponge board clamp 2 and the sponge board, moves to the adhesive station for alignment. The transverse insertion cylinder 222 retracts, and the lifting plate 223 withdraws from the bottom of the sponge board. The robotic arm 1 drives the clamp base 21 to apply downward pressure, making the sponge board tightly adhere to the mattress body. Finally, the negative pressure air source is cut off to release the suction effect of the negative pressure suction cup 24, completing the entire sponge board bonding operation. Compared to Embodiment 1, this embodiment eliminates the entire pressing module, reduces the number of cylinders and board components, simplifies the clamp structure, simplifies the assembly process, reduces the number of potential failure points, and lowers equipment manufacturing and maintenance costs. However, without the pressure plate to limit and constrain the sides of the board, relying solely on the lifting of the two side picking plates and the negative pressure adsorption in the middle, the edges of the sponge board are prone to slight warping during high-speed transfer. The alignment accuracy is lower than that of Embodiment 1 and Embodiment 2 equipped with pressure plates. It is suitable for mass standardized production of sponge boards of conventional thickness and standard size.

[0042] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the appended claims.

Claims

1. A smart mattress production line, comprising a foam board gluing station, characterized in that, The sponge board adhesive station is equipped with a robotic arm (1) and a sponge board clamp (2); the sponge board clamp (2) includes a clamp base (21) and several layered material handling modules (22); the clamp base (21) is rectangular frame-shaped, and the top center of the clamp base (21) is connected to the end of the robotic arm (1); monitoring cameras (25) are installed at the four corners of the clamp base (21), and the monitoring cameras (25) are arranged facing the inside of the clamp base (21); the layered material handling modules (22) are arranged around the clamp base (21). The layered material handling module (22) includes a lifting cylinder (221), a transverse insertion cylinder (222), and a material handling plate (223). The cylinder body end of the lifting cylinder (221) is installed on the outside of the fixture base (21). The output end of the lifting cylinder (221) is connected to the transverse insertion cylinder (222). The telescopic end of the transverse insertion cylinder (222) is equipped with the material handling plate (223). The material handling plate (223) is located on the outside of the bottom of the fixture base (21) and is arranged facing the inside of the fixture base (21).

2. The intelligent mattress production line according to claim 1, characterized in that, The sponge board clamp (2) also includes an edge adjustment mechanism (23), which includes an adjustment plate (231), a guide rod (232), and an adjustment drive structure (233). There are four adjustment plates (231), which are respectively arranged on the four sides of the clamp base (21). The guide rod (232) and the adjustment drive structure (233) are respectively arranged in the four directions of the clamp base. The guide rod (232) passes through the outside of the clamp base (21) and is slidably connected to the clamp base (21). The outer end of the guide rod (232) is fixedly connected to the adjustment plate (231) on the corresponding side. The adjustment drive structure (233) drives the adjustment plate (231) on the corresponding side to move along the guide rod (232) on the corresponding side. The cylinder end of the lifting cylinder (221) is installed on the adjustment plate (231).

3. The intelligent mattress production line according to claim 2, characterized in that, The adjustment drive structure (233) includes a servo motor (2331), a lead screw (2332), a nut sleeve (2333), and an anti-rotation guide rod (2334). The servo motor (2331) is connected to the lead screw (2332) for transmission. The nut sleeve (2333) is fitted onto the lead screw (2332). The anti-rotation guide rod (2334) is arranged parallel to the lead screw (2332) and slidably embedded outside the nut sleeve (2333). The nut sleeve (2333) extends outward and is provided with a connecting tube (2335). The nut sleeve (2333) is fixedly connected to the adjustment plate (231) through the connecting tube (2335).

4. The intelligent mattress production line according to claim 1, characterized in that, The clamp base (21) is provided with a plurality of negative pressure suction cups (24), the negative pressure suction cups (24) are arranged facing the bottom of the clamp base (21), and the negative pressure suction cups (24) are connected to a controllable negative pressure air source.

5. A smart mattress production line according to any one of claims 1-4, characterized in that, The layered material handling module (22) has two sets of lifting cylinders (221), transverse insertion cylinders (222) and material handling plates (223), which are arranged side by side in a corresponding manner.

6. A smart mattress production line according to claim 5, characterized in that, The layered material handling module (22) is also provided with a second lifting cylinder (225), a transverse cylinder (226) and a pressure plate (227); the output end of the second lifting cylinder (225) is connected to the transverse cylinder (226), the extension end of the transverse cylinder (226) is equipped with the pressure plate (227), the pressure plate (227) is arranged towards the inside of the fixture base (21), and the second lifting cylinder (225), the transverse cylinder (226) and the pressure plate (227) are installed as a whole in the middle position of the two sets of lifting cylinders (221).

7. A smart mattress production line according to claim 6, characterized in that, The width of the pressure plate (227) is greater than that of the take-up plate (223), and the bottom surface of the pressure plate (227) is provided with raised anti-slip texture (224).

8. A smart mattress production line according to claim 4, characterized in that, The robotic arm (1) drives the sponge board clamp (2) to complete the clamping, transfer, and bonding of stacked sponge boards, including the following steps: Step 1: The robotic arm (1) drives the clamp base (21) to move horizontally above the top layer of the stacked sponge board; Step 2: The lifting cylinder (221) descends, aligning the material picking plate (223) with the gap between the top layer sponge board and the second-to-top layer sponge board; Step 3: The transverse insertion cylinder (222) extends and inserts the material picking plate (223) into the gap between the two layers of sponge board. At the same time, the negative pressure suction cup (24) is turned on to adsorb and fix the sponge board from the middle of the sponge board. Step 4: The lifting cylinder (221) is raised to completely lift the top layer of sponge board; Step 5: The robotic arm (1) drives the sponge board clamp (2) to move the sponge board above the adhesive station and complete the alignment. Step 6: The transverse insertion cylinder (222) retracts, the material taking plate (223) is removed from the bottom of the sponge board, the sponge board falls naturally, the clamp base (21) applies downward pressure, pressing the sponge board tightly against the mattress body, and finally the negative pressure suction cup (24) is closed to release the adsorption, completing the bonding operation.

9. A smart mattress production line according to claim 5, characterized in that, The robotic arm (1) drives the sponge board clamp (2) to complete the clamping, transfer, and bonding of stacked sponge boards, including the following steps: Step 1: The robotic arm (1) drives the clamp base (21) to move horizontally above the top layer of the stacked sponge board; Step 2: The lifting cylinder (221) descends, aligning the material picking plate (223) with the gap between the top layer sponge board and the second-to-top layer sponge board; Step 3: The transverse insertion cylinder (222) extends and inserts the picking plate (223) into the gap between the two layers of sponge board; the two sets of picking plates (223) move in a staggered manner, with one picking plate lifting the top layer of sponge board and the other picking plate pressing the sponge board to prevent the sponge boards from sticking together. Step 4: After the lifting cylinder (221) on one side slightly lifts the sponge board, the material picking plate (223) on the other side switches to the lifting state, and the entire top sponge board is completely lifted. Step 5: The robotic arm (1) drives the sponge board clamp (2) to move the sponge board above the adhesive station and complete the alignment. Step 6: The transverse insertion cylinder (222) retracts, the material picking plate (223) is removed from the bottom of the sponge board, the sponge board falls naturally, and the robotic arm (1) drives the clamp base (21) to press down the sponge board as a whole, so as to complete the bonding with the mattress body.

10. A smart mattress production line according to claim 6, characterized in that, The robotic arm (1) drives the sponge board clamp (2) to complete the clamping, transfer, and bonding of stacked sponge boards, including the following steps: Step 1: The robotic arm (1) drives the clamp base (21) to move horizontally above the top layer of the stacked sponge board; Step 2: The lifting cylinder (221) descends, aligning the material picking plate (223) with the gap between the top layer sponge board and the second-to-top layer sponge board; Step 3: The transverse insertion cylinder (222) extends and inserts the picking plate (223) into the gap between the two layers of sponge board; the two sets of picking plates (223) move in a staggered manner, with one picking plate lifting the top layer of sponge board and the other picking plate pressing the sponge board to prevent the sponge boards from sticking together. Step 4: After the lifting cylinder (221) on one side slightly lifts the sponge board, the material picking plate (223) on the other side switches to the lifting state, and at the same time the pressing plate (227) moves downward to clamp the sponge board. Step 5: The robotic arm (1) drives the sponge board clamp (2) to move the sponge board above the adhesive station and complete the alignment. Step 6: The transverse insertion cylinder (222) retracts, the material picking plate (223) is removed from the bottom of the sponge board, the sponge board falls and adheres to the mattress body, and the robotic arm (1) drives the clamp base (21) to press down the sponge board as a whole to complete the bonding.

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