An automatic mattress positioning and buttoning machine and a control system thereof

Abstract

The present application relates to the technical field of mattress manufacturing automation equipment, and specifically discloses a mattress automatic positioning and button threading machine and a control system thereof, which comprises a rack, a turnover mechanism, a clamping mechanism and a button threading execution mechanism; the turnover mechanism turns a horizontally placed mattress to a vertical posture; the clamping mechanism adaptively adjusts the clamping distance for mattresses of different specifications through a thickness detection sensor; the button threading execution mechanism comprises a button threading needle and a pushing assembly; the head of the button threading needle accommodates a string spring belt rubber head in a slot, and the string spring belt rubber head is pushed out by the pushing assembly and then returns to the original path. The automatic control system comprises a numerical control positioning module, a man-machine interaction module and a visual programming module; the visual programming module provides a graphical editing interface of a point matrix with multiple rows and multiple columns, supports click selection of button threading points, and configures process parameters such as thickness selection, interval length and bottom edge distance; a leakage detection module automatically identifies and marks holes that are not successfully threaded. The present application realizes automatic button threading of mattresses and effectively eliminates the hidden danger of missed holes.

Description

Technical Field

[0001] This application relates to the field of automated equipment technology for mattress manufacturing, and in particular to an automatic mattress positioning and fastening machine and its control system. Background Technology

[0002] In mattress manufacturing, the snap-on spring assembly is a crucial step. Snap-on spring assembly involves using snap-on pins to thread the spring strap through the already assembled spring core (commonly known as the "spring strap"), and then securing the end of the spring strap with an anti-slip button on the other side of the mattress. This firmly connects the spring cores together, ensuring the overall structural stability of the mattress.

[0003] The existing manual fastening method has the following prominent problems: Mattresses are typically large and heavy, requiring workers to repeatedly move, flip, and climb to adjust their position. Threading the fasteners requires considerable arm strength to penetrate multiple layers of material, and prolonged exposure to this work can easily lead to muscle strain.

[0004] Manual buckle insertion relies on experience and manual visual positioning. However, manual visual positioning has significant deviations, and the results may vary between different workers or even between the same worker at different times. This can lead to uneven and non-standard buckle positions on the final product, affecting the consistency of appearance quality and structural strength.

[0005] Besides the experience-based issues associated with manual button threading, the physical properties of the mattress also play a role. Mattresses are flexible, multi-layered, heterogeneous materials, and their thickness undergoes significant non-linear compression under clamping conditions. The uniformity of the clamping force affects the penetration accuracy of the button threading needle. Therefore, due to the non-rigid nature of mattress materials, precise positioning cannot be achieved as in rigid material processing such as PCB drilling or metal stamping.

[0006] The arrangement of the fastening points on a mattress varies flexibly depending on product specifications and customer needs; it is not a fixed matrix arrangement. Furthermore, the fastening needle, carrying a spring and rubber tip, needs to penetrate multiple layers of material before being precisely released on the other side. Existing automatic piercing equipment, such as sewing machines and button-attaching machines, mostly only involves the piercing of the needle and the thread passing through, without including the subsequent release process. Summary of the Invention

[0007] This application provides an automatic mattress positioning and fastening machine and its control system, which solves the technical problems of high intensity, poor positioning accuracy, easy leakage of holes, and low efficiency in existing mattress fastening work.

[0008] In a first aspect, this application proposes an automatic mattress positioning and fastening machine, comprising: frame; A flipping mechanism, which is mounted on the frame, is used to flip a mattress lying flat on the worktable to an upright position; A clamping mechanism, comprising an upper clamping assembly and a lower clamping assembly disposed opposite to each other, and a thickness detection sensor for detecting the thickness of the mattress, wherein the detection signal of the thickness detection sensor is used to control the clamping distance between the upper clamping assembly and the lower clamping assembly; The fastening actuator includes a fastening pin and a fastening pin pushing assembly. The head of the fastening pin is provided with a groove for receiving the spring-loaded rubber head. The fastening pin pushing assembly is used to push the spring-loaded rubber head out of the groove and return the fastening pin along its original path.

[0009] In the above solution, the mattress is automatically flipped to an upright position by a flipping mechanism, which solves the problem of high labor intensity and safety hazards caused by workers having to repeatedly move, flip, and climb to adjust the position of the mattress in the existing technology; the thickness detection sensor detects the thickness of the mattress and adaptively controls the clamping distance, which solves the problem of poor fastening accuracy caused by the variety of mattress thicknesses and uneven clamping force; the fastening needle head groove carries a spring with a rubber head to penetrate the mattress and is pushed out by the pushing component, and the fastening needle returns along the original path, which solves the technical problem that the existing automatic piercing equipment can only thread the needle and cannot complete the "penetration and push-out" process, thus realizing the automated closed loop of the fastening process.

[0010] As one embodiment of the first aspect: the flipping mechanism includes a flipping drive motor and a flipping frame, the flipping frame being able to rotate about a horizontal axis, so that the mattress placed thereon can switch between a horizontal posture and an upright posture. The flipping angle of the flipping mechanism ranges from 0° to 90°.

[0011] In the above solution, the flipping frame switches back and forth within the range of 0° to 90° around the horizontal axis to solve the problem that the mattress cannot automatically switch between the two postures of horizontal loading and vertical fastening, so as to achieve stable switching of the loading and fastening station postures and avoid manually flipping the mattress.

[0012] As one embodiment of the first aspect: the upper clamping assembly and the lower clamping assembly respectively include a clamping cylinder and a clamping bar; The thickness detection sensor is located on one side of the lower clamping assembly and is used to detect the thickness value of the mattress placed between the upper clamping assembly and the lower clamping assembly. The clamping cylinder adaptively adjusts the clamping stroke according to the thickness value.

[0013] In the above solution, the thickness value of the mattress is obtained in real time by a thickness detection sensor and the clamping stroke is adaptively adjusted by the clamping cylinder. This can solve the problem of repeatedly adjusting the clamping stroke of mattresses of different sizes by manual means, so that mattresses of different thicknesses can obtain uniform and stable clamping force and improve the penetration accuracy of the fastener pin.

[0014] As one embodiment of the first aspect: the fastening actuator further includes an inward pushing component, which is disposed at the tail of the fastening needle bar and is used to push the spring belt rubber head out of the slot after the fastening needle penetrates the mattress; The button-feeding needle pushing component is connected to the inner pushing component in a transmission manner. After the inner pushing component completes the pushing action, the button-feeding needle is driven to retract in the opposite direction along the needle insertion path.

[0015] In the above solution, this application uses an internal pusher component to push the spring belt rubber head out of the slot along the axis after the threading pin penetrates the mattress. Then the threading pin retracts along the original path, so that the spring belt rubber head is accurately released on the other side of the mattress, realizing the threading cycle of material penetration, push-out release and retraction along the original path. The rubber head release position is accurate and does not jam the material.

[0016] Secondly, this application proposes an automatic control system for controlling a mattress automatic positioning and fastening machine according to the first aspect, the system comprising: The CNC positioning module includes an X-axis motion mechanism and a Z-axis motion module, which are used to control the buckle-fastening actuator to adjust its position in the horizontal and vertical directions; Human-computer interaction module, wherein the human-computer interaction module is provided with a coordinate display submodule and a coordinate calibration zeroing submodule human-computer interaction interface; The visual programming module is set in the human-computer interaction interface and includes a point matrix editing area. The point matrix editing area displays the buckle point configuration array of rows L1 to Ln and multiple columns in a graphical manner. It supports users to select or edit the arrangement of buckle positions by clicking on the points and supports the configuration of process parameters. The process parameters include at least thickness selection, interval length and bottom edge distance.

[0017] In the above solution, the X-axis and Z-axis motion modules of the CNC positioning module enable the fastening actuator to be positioned in the horizontal and vertical directions by coordinate positioning, thus solving the technical problem of large deviations in manual visual positioning. The visual programming module provides a graphical point matrix editing interface, allowing users to arrange fastening positions in any way and configure process parameters by clicking on points. This solves the problem of the difficulty in programming when the arrangement of mattress fastening points changes flexibly with product specifications, and allows non-professionals to quickly complete the programming of the fastening scheme.

[0018] As one embodiment of the second aspect: the X-axis motion mechanism includes an X-axis drive unit and an X-axis guide assembly, used to drive the buckle actuator to move in the left and right direction to align with the gap of the frame clamping rod; The Z-axis motion module includes a Z-axis drive unit and a Z-axis guide assembly, which are used to drive the buckle actuator to move in the up and down direction to the corresponding pin height position; The coordinate calibration and zeroing module includes an X-axis calibration button and a Z-axis zeroing button.

[0019] In the above solution, the coordinate origin reference of the fastening point is established by using the X-axis calibration button and the Z-axis zeroing button, which solves the technical problems of equipment installation error and coordinate reference drift after mattress specification change, so that the fastening point calculation has a unified coordinate reference.

[0020] As one embodiment of the second aspect: the number of rows n in the point matrix editing area is an integer from 6 to 12; each point in the point matrix editing area is represented by a circular icon, the selected points are marked with a first color, and the unselected points are marked with a second color; The process parameters also include the current serial number parameter and the real-time display parameter of the pin position.

[0021] In the above solution, the selected state is distinguished by a matrix of 6 to 12 rows of points and the color of the circular icons, making the button arrangement clear at a glance and solving the technical problem that complex patterns are difficult to edit and check intuitively; by displaying the current row number parameters and the pin position in real time, the operator can keep track of the work progress and the current position of the button.

[0022] As one embodiment of the second aspect: the system further includes a leak detection module, which is communicatively connected to the human-machine interface, and is used to detect holes that have not successfully passed through the spring belt after a row of buckle-fastening actions are completed, and to display a warning in a third color at the corresponding point in the point matrix editing area.

[0023] In the above solution, the leak detection module automatically detects and marks the holes that were not successfully passed through after a row of buckles are completed. This eliminates the need to check each hole for missing buckles, making it easy to find and eliminate the problem of missing holes.

[0024] As one embodiment of the second aspect: the CNC positioning module performs the following steps: S1. The mattress is transported to the fastening station and laid flat. The clamping mechanism is activated to compress and clamp the two sides of the mattress. At the same time, the thickness data of the mattress is obtained by the thickness detection sensor and the clamping amount is adjusted according to the thickness data. S2. Control the flipping mechanism to flip the mattress from a horizontal position to an upright position; S3. Perform coordinate calibration operation. Adjust the horizontal position of the fastening actuator through the X-axis motion mechanism so that the fastening pin is aligned with the gap of the frame clamping rod. Perform X-axis calibration and Z-axis zeroing operation. S4. In the point matrix editing area of ​​the human-computer interaction interface, select the desired buckle arrangement pattern and process parameters, including thickness selection, interval length and bottom edge distance; S5. Based on the selected fastening point, control the CNC positioning module to drive the fastening actuator to move to the corresponding pin position height; S6. Control the fastening actuator to perform the fastening action. The fastening needle carries the spring belt through the mattress, and then the spring belt rubber head is pushed out by the fastening needle push component. The fastening needle returns along the original path. S7. Repeat steps S5-S6 until the buckle operation of all points in the current row is completed, perform a leak detection and prompt for unsuccessful points to be re-attached.

[0025] In the above scheme, the entire process from S1 to S7 includes feeding, clamping, flipping, coordinate calibration, scheme selection, positioning, fastening, and checking for omissions and making corrections, achieving automatic conveying and CNC positioning, and then executing automatic fastening and omission checking.

[0026] As an embodiment of the second aspect: in step S4, the point matrix editing area presets various specifications of interlocking patterns, and the interlocking patterns are identified by name and associated with a set of default process parameters; When any name identifier is selected and triggered by the user, the corresponding buckle point configuration and process parameters are loaded.

[0027] In the above solution, by pre-setting specification templates and loading them by name with one click, it is possible to achieve small-batch production of multiple varieties without having to reconfigure each batch.

[0028] Other features and advantages of the invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention may be realized and obtained by means of the structures particularly pointed out in the written description and the accompanying drawings.

[0029] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0030] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram illustrating the application scenario of the automatic mattress positioning and fastening machine in an embodiment of the present invention; Figure 2 This is a schematic diagram showing the first structural details of the frame of the automatic mattress positioning and fastening machine in an embodiment of the present invention; Figure 3 This is a schematic diagram showing the details of the second structure of the frame of the automatic mattress positioning and fastening machine in an embodiment of the present invention; Figure 4 This is a schematic diagram of the buckle actuator in an embodiment of the present invention; Figure 5 This is a schematic diagram of the button pin structure in an embodiment of the present invention; Figure 6 This is a schematic diagram illustrating the combined action of the CNC positioning module and the fastening actuator in an embodiment of the present invention; Figure 7 This is a diagram of the action control interface in an embodiment of the present invention; Figure 8 This is the working interface point matrix in the embodiment of the present invention; Figure 9 In this embodiment of the invention, it becomes an editing interface; Figure 10 This is a schematic diagram of the control system in an embodiment of the present invention. Detailed Implementation

[0031] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention. Example

[0032] This application discloses an automatic mattress positioning and fastening machine, comprising: a frame; a flipping mechanism disposed on the frame for flipping a mattress placed flat on a worktable to an upright position; a clamping mechanism including an upper clamping component and a lower clamping component disposed opposite to each other, and a thickness detection sensor for detecting the thickness of the mattress, wherein the detection signal of the thickness detection sensor is used to control the clamping distance between the upper clamping component and the lower clamping component; and a fastening execution mechanism including a fastening pin and a fastening pin pushing component, wherein the head of the fastening pin is provided with a groove for accommodating a spring with a rubber head, and the fastening pin pushing component is used to push the spring with a rubber head in the groove and return the fastening pin along its original path.

[0033] In this application, as Figure 1 As shown, the automatic mattress positioning and fastening machine mainly includes a frame 1. A lifting conveyor 8 transports the mattress 7 to be pierced to the clamping mechanism 3 of the frame. The piercing is controlled by a control system 9. The frame 1, as the supporting skeleton of the entire machine, is made of welded steel and has sufficient rigidity and load-bearing capacity to support the weight of the mattress and the force applied during the fastening operation. The frame 1 is fixed to the edge of the mounting bracket 10; the control system 9 is a control host.

[0034] The flipping mechanism 2 is mounted on the frame 1 and includes a flipping drive and a flipping transmission mechanism 22. The flipping transmission mechanism 22 is rotatably connected to the frame 1 via a horizontal rotating shaft 23. The output shaft of the flipping drive is connected to the flipping transmission mechanism 22, which drives the horizontal rotating shaft 23 to rotate. A lower clamping assembly 32 is fixed to the horizontal rotating shaft 23. The working surface of the lower clamping assembly 32 is used to support the mattress. Driven by the flipping drive, the flipping transmission mechanism 22 can switch back and forth between a horizontal position (0° position, where the mattress lies flat on the lower clamping assembly 32) and an upright position (90° position, where the mattress stands vertically). The flipping angle can be set between 0° and 90° as needed.

[0035] The clamping mechanism 3 includes an upper clamping assembly 31 and a lower clamping assembly 32. The upper clamping assembly 31 and the lower clamping assembly 32 each include a clamping cylinder 11 and a clamping bar 33; wherein the clamping cylinder 11 serves as a power element, and the clamping bar 33 serves as a pressure-bearing component that is in direct contact with the mattress.

[0036] In this application, the thickness detection sensor is disposed on one side of the lower clamping assembly 32, or it can be integrated on the side of the lower clamping assembly 32. The thickness detection sensor is set according to the user's installation scenario. It includes non-contact detection elements such as infrared ranging sensors, ultrasonic sensors or laser displacement sensors.

[0037] In one embodiment of this application, a thickness detection sensor is used to detect the thickness of the mattress. The mattress is placed between the upper clamping assembly 31 and the lower clamping assembly 32, and the thickness value is transmitted to the control system. The control system calculates the corresponding stroke of the clamping cylinder 11 based on the thickness value, and outputs a control signal to drive the clamping cylinder 11 to move, thereby adjusting the clamping distance. In a practical embodiment of this application, the detection range of the thickness detection sensor covers 20~150 mm.

[0038] The CNC positioning module drives the fastening actuator 4, which includes a fastening needle 43, a fastening needle pushing component 44, and an inward pushing component 46. The main body of the fastening needle 43 is a slender cylindrical steel needle with sufficient rigidity and sharpness to penetrate the multiple layers of materials in a mattress. In actual penetration scenarios, the mattress uses multiple layers of materials, including fabric layers, foam layers, and spring layers. The head of the fastening needle 43, i.e., the end away from the needle tip, has a groove 431. The groove 431 is a recess that matches the shape of the rubber head of the spring band, i.e., the groove can be semi-circular or rectangular in cross-section, used to accommodate and fix the rubber head end of the spring band 432 before fastening. The inward pushing component 46 is located at the tail of the needle bar of the fastening needle 43 and can slide axially in the internal cavity or side guide groove of the fastening needle 43. The button-threading push assembly 44 is connected to the inner push component 46 via a transmission. When the button-threading needle 43, carrying the spring-loaded rubber head 432, penetrates the mattress to a predetermined depth, the button-threading push assembly 44 drives the inner push component 46 to push the spring-loaded rubber head out of the slot 431, causing it to detach from the button-threading needle 43 and remain on the other side of the mattress. Subsequently, the button-threading push assembly 44 continues to drive the button-threading needle 43 to return to the initial position along the needle insertion path, completing a complete button-threading cycle.

[0039] This embodiment automates the mattress fastening process through the above structure: the flipping mechanism replaces manual flipping, the clamping mechanism adapts to replace manual fixing, and the fastening execution mechanism automatically completes the material carrying, penetration, and release, effectively solving the technical problems of high labor intensity, poor positioning accuracy, and lack of a release process in the prior art.

[0040] Example 2: The flipping mechanism includes a flipping drive motor and a flipping frame. The flipping frame can rotate around a horizontal axis, allowing the mattress placed on it to switch between a horizontal and an upright position. The flipping angle range of the flipping mechanism is 0° to 90°.

[0041] In this application, as Figure 3 As shown, in one embodiment, the flipping drive component of the flipping mechanism 2 is a flipping drive cylinder 21, and the output shaft of the flipping drive cylinder 21 is connected to the horizontal rotating shaft 23 via the flipping transmission mechanism 22. In another embodiment, the flipping drive component is a flipping drive motor (servo motor), which can more precisely control the flipping angle and angular velocity. The flipping frame (i.e., the flipping structure with the lower clamping component 32 fixed) reciprocates between 0° and 90° positions around the horizontal rotating shaft 23: at the 0° position, the mattress is laid flat on the lower clamping component 32, which is convenient for loading and clamping; at the 90° position, the mattress stands vertically, so that the side of the mattress faces the fastening actuator 4, which is convenient for fastening operations. Through precise control of the flipping angle, it is ensured that the mattress does not slip during the flipping process, and a stable transition between the horizontal loading and vertical fastening postures is achieved.

[0042] Example 3: The upper clamping assembly and the lower clamping assembly each include a clamping cylinder and a clamping bar; a thickness detection sensor is set on one side of the lower clamping assembly to detect the thickness value of the mattress placed between the upper clamping assembly and the lower clamping assembly; the clamping cylinder adaptively adjusts the clamping stroke according to the thickness value.

[0043] In this application, as Figure 2 As shown, the thickness detection sensor of the clamping mechanism 3 detects the mattress thickness value t in real time and transmits it to the control system. The control system then calculates the required stroke of the clamping cylinder 11 and drives it to achieve adaptive adjustment of the clamping distance. The clamping bar 33, as a pressure-bearing component in direct contact with the mattress, applies uniform pressure to both sides of the mattress under the push of the clamping cylinder 11. For mattresses of different thicknesses (such as thin mattresses and thick mattresses), the clamping stroke is automatically adjusted, eliminating the need for repeated manual adjustments and ensuring the uniformity of the clamping force, thus providing a stable positioning basis for the penetration accuracy of the fastener pin.

[0044] Example 4: The fastening actuator also includes an inner pusher component, which is located at the tail of the fastening needle shank and is used to push the spring-loaded rubber head out of the slot after the fastening needle penetrates the mattress; the fastening needle pushing component is connected to the inner pusher component in a transmission manner, and after driving the inner pusher component to complete the pushing action, it drives the fastening needle to retract in the opposite direction along the needle insertion path.

[0045] In this application, as Figure 4 , Figure 5 As shown, the button-threading push assembly 44 and the inner push component 46 are connected by a transmission, forming a "push material first, then retract the needle" action sequence: after the button-threading needle 43 carries the spring-loaded rubber head 432 through the mattress to a predetermined depth, the button-threading push assembly 44 first drives the inner push component 46 to slide along the needle shaft axis, pushing the spring-loaded rubber head 432 in the slot 431 to the other side of the mattress, achieving precise release of the rubber head at the designated position; then the button-threading push assembly 44 drives the button-threading needle 43 to retract along the needle insertion path back to the initial position. This "carry material through - push out and release - retract along the original path" sequence design ensures that the spring-loaded rubber head is released at the same depth position each time, the rubber head is accurately positioned, does not jam, and does not fall off, while the retraction of the button-threading needle along the original path avoids secondary damage to the mattress.

[0046] Example 5: An automatic control system for controlling the automatic mattress positioning and fastening machine described in any one of Examples 1 to 4. The system includes: a CNC positioning module, which includes an X-axis motion mechanism and a Z-axis motion module, for controlling the fastening actuator to adjust its position in the horizontal and vertical directions; a human-machine interface module, which has a coordinate display sub-module and a coordinate calibration zeroing sub-module; and a visual programming module, which is set in the human-machine interface and includes a point matrix editing area. The point matrix editing area graphically displays a fastening point configuration array of rows L1 to Ln and multiple columns, allowing users to select or edit the arrangement of fastening positions by clicking on the points, and supports configuring process parameters, including at least thickness selection, interval length, and bottom edge distance.

[0047] In this application, as Figure 10 and Figure 6 As shown, the CNC positioning module 51 includes an X-axis motion mechanism 511 and a Z-axis motion module 512. The X-axis motion mechanism 511 includes an X-axis drive unit 5111 and an X-axis guide assembly 5112, used to drive the fastening actuator 4 to move horizontally to align with the clamping gap of the frame 1. The Z-axis motion module 512 includes a Z-axis drive unit 5121 and a Z-axis guide assembly 5122, used to drive the fastening actuator 4 to move vertically to the corresponding pin height position. The X-axis drive unit 5111 and the Z-axis drive unit 5121 can be in the form of a servo motor with a precision ball screw pair or a linear motor, and the X-axis guide assembly 5112 and the Z-axis guide assembly 5122 can be in the form of a linear guide slider assembly. Through the combined motion of the X-axis motion mechanism 511 and the Z-axis motion module 512, the fastening actuator 4 can reach any target point in the pre-set three-dimensional space.

[0048] The human-computer interaction module 52 includes a coordinate display submodule 521 and a coordinate calibration and zeroing module 522. The coordinate display submodule 521 displays the current X and Z coordinate values ​​in real time; the coordinate calibration and zeroing module 522 includes an X-axis calibration button and a Z-axis zeroing button. When using the device for the first time or changing the mattress size, the operator can manually adjust the position of the fastening actuator 4 through the motion control interface so that the fastening pin 43 is accurately aligned with the middle gap of the clamping rod of the frame 1. Then, the operator presses the X-axis calibration button to set this position as the X-axis origin reference, and presses the Z-axis zeroing button to clear the Z-axis, thereby establishing the coordinate reference for all subsequent fastening points.

[0049] The visual programming module 53 is located in the human-computer interaction interface, and its core area is the point matrix editing area 531. The point matrix editing area 531 displays the layout of the interlocking points in the form of a two-dimensional grid with L1 to Ln rows (in this embodiment, the number of rows n is an integer between 6 and 12, preferably 9 rows) × multiple columns, and each intersection is represented by a circular icon.

[0050] In one specific embodiment, the user selects or deselects a buttonhole point by directly clicking a circular icon. Selected points are marked with a first color, usually red. Unselected points are marked with a second color, usually a hollow circle. During parameter configuration, buttonhole patterns of any arrangement can be quickly arranged through click-based editing. Combined with process parameter configuration, this solves the problem of traditional buttonhole solutions requiring manual measurement and positioning point by point. Buttonhole patterns include specific rule matrices, staggered arrangements, and local densification, etc. In this embodiment, through the combined action of the CNC positioning module, the human-computer interaction module, and the visual programming module, the graphical programming and CNC of the fastening points can be accurately positioned, eliminating the need for manual visual inspection during production. The arrangement of the points is flexible and varied, and editing is simpler.

[0051] Example 6: The X-axis motion mechanism includes an X-axis drive unit and an X-axis guide assembly, used to drive the buckle actuator to move in the left and right direction to align with the gap of the frame clamping rod; In this application, the Z-axis motion module includes a Z-axis drive unit and a Z-axis guide assembly, which are used to drive the buckle actuator to move in the up and down direction to the corresponding pin height position; the coordinate calibration and zeroing module includes an X-axis calibration button and a Z-axis zeroing button.

[0052] In this application, as Figure 7 As shown, the motion control interface provides manual adjustment functions, including shortcut buttons for fastening positions 1 to 9, a master fastening control button, a real-time X / Z coordinate display area, X calibration / Z zeroing buttons, left / right / up / down direction control buttons, clamp opening / clamp compression control buttons, belt conveyor control buttons, horizontal / vertical flip control buttons, and a stop / emergency stop button. After manually adjusting the fastening pin 43 to align with the gap in the frame clamping rod using the direction control buttons, the operator presses the X-axis calibration button to establish the X-axis origin and presses the Z-axis zeroing button to clear the Z-axis, thus completing the establishment of the coordinate reference. This coordinate reference establishment method is simple and reliable, solving the coordinate drift problem caused by equipment installation errors and mattress specification changes. All subsequent fastening points are automatically calculated under this reference, ensuring consistent positioning.

[0053] Example 7: The number of rows n in the point matrix editing area is an integer between 6 and 12; each point in the point matrix editing area is represented by a circular icon, the selected points are marked with the first color, and the unselected points are marked with the second color; the process parameters also include the current row number parameter and the real-time display parameter of the pin position.

[0054] In this application, as Figure 8 As shown, the point matrix editing area 531 displays the layout of the fastening points using a matrix of circular icons. Selected points are marked with red fill, while unselected points are marked with hollow circles. The row and column information and the selection status are clear at a glance, allowing for intuitive verification of whether the fastening pattern meets the process requirements. Figure 9 As shown, the point matrix editing area 531 also has a process parameter configuration area, including: a name drop-down box, which is used to select a preset specification template, such as "20×150" or "custom specification"; a thickness selection control; an interval length input box, in millimeters, used to set the center distance between two horizontally adjacent fastening points; and a bottom edge distance input box, used to set the offset of the bottom row of fastening points from the bottom edge of the mattress. The current row number parameter indicates which row is currently being processed; The pin position is displayed in real time, showing the current X and Z coordinate values ​​of the button pin 43. The "Retrieve / Load" button indicates that point configuration data needs to be exported or imported. This application displays the real-time status of the button insertion process based on color coding, current row number, and pin position, allowing operators to determine the button insertion progress and current pin position without approaching the equipment, thereby improving the actual efficiency of the operation.

[0055] Example 8: The system also includes a leak detection module, which is connected to the human-machine interaction module. It is used to detect the holes that have not successfully passed through the spring belt after a row of buckle-fastening actions are completed, and to display a warning in the third color at the corresponding point in the point matrix editing area.

[0056] In this application, the leak detection module 54 is communicatively connected to the human-machine interface module 52. Its detection principle involves monitoring the execution feedback signals of each threading action (such as cylinder stroke completion signals, push pressure sensor signals, etc.) to determine whether the point has successfully passed the spring belt. After all threading actions in a row (e.g., all selected points in row L1) have been completed, the leak detection module 54 summarizes and analyzes the execution results of each point in that row. For points that fail to pass successfully, it sends a warning command to the human-machine interface module 52, causing the corresponding circular icon in the point matrix editing area 531 to display a warning in a third color (e.g., orange), prompting the operator to re-thread the point. Through this closed-loop detection mechanism, unthreaded holes are automatically marked and prompted for re-threading, preventing leaks from flowing into the next process and effectively eliminating the potential for leaks.

[0057] Example 9: The CNC positioning module executes the following steps: S1. The mattress is transported to the fastening station and laid flat. The clamping mechanism is activated to compress and clamp both sides of the mattress. At the same time, the thickness data of the mattress is obtained through the thickness detection sensor, and the clamping amount is adjusted according to the thickness data; S2. The flipping mechanism is controlled to flip the mattress from a horizontal position to an upright position; S3. The coordinate calibration operation is performed. The horizontal position of the fastening actuator is adjusted through the X-axis motion mechanism so that the fastening pin is aligned with the gap of the clamping rod of the frame. The X-axis calibration and Z-axis zeroing operations are performed; S4. The point matrix is ​​programmed in the human-machine interface. S5. Select the desired stitching pattern and process parameters for the selected stitching area. Process parameters include thickness selection, interval length, and bottom edge distance. S6. Based on the selected stitching points, control the CNC positioning module to drive the stitching actuator to move to the corresponding pin insertion position height. S7. Control the stitching actuator to perform the stitching action. The stitching needle carries the spring strip through the mattress, and then the spring strip rubber head is pushed out by the stitching needle push component. The stitching needle returns along the original path. S8. Repeat steps S5-S6 until the stitching operation of all points in the current row is completed. Perform a leak detection and prompt for re-stitching unsuccessful points.

[0058] In this application, the complete workflow of the automatic mattress positioning and fastening machine is executed by the CNC positioning module 51: Step S1 indicates loading and clamping: the mattress is transported to the fastening station and laid flat, and the clamping mechanism 3 is started to compress and clamp both sides of the mattress; at the same time, the thickness data of the mattress is obtained through the thickness detection sensor 34, and the clamping amount is adjusted according to the thickness data, that is, the clamping cylinder 11 is driven to adaptively adjust the clamping stroke.

[0059] Step S2 indicates flipping: control the flipping mechanism 2 to flip the mattress from a horizontal position to an upright position, so that the side of the mattress faces the fastening actuator 4.

[0060] Step S3 indicates coordinate calibration: Perform coordinate calibration by adjusting the horizontal position of the fastening actuator 4 via the X-axis motion mechanism 511, so that the fastening pin 43 is aligned with the gap of the clamping rod on the frame 1; then perform X-axis calibration and Z-axis zeroing operations to establish the origin reference of the coordinate system for calculating all subsequent fastening points. If it is a routine continuous production of products of the same specification, this step does not need to be repeated.

[0061] Step S4 indicates selecting the fastening scheme: In the point matrix editing area 531 of the human-computer interaction interface, select the desired fastening arrangement pattern and process parameters. The process parameters include thickness selection, interval length, and bottom edge distance. The system automatically calculates the XZ coordinate sequence corresponding to all selected points.

[0062] Step S5 indicates positioning: Based on the selected pin insertion point, the CNC positioning module 51 drives the pin insertion actuator 4 to move to the corresponding pin insertion position height; the pin insertion position display parameters on the human-machine interface are updated synchronously with the current X and Z coordinate values.

[0063] Step S6 indicates fastening: Control the fastening actuator 4 to perform the fastening action. The fastening needle 43 carries the spring belt through the mattress, and then the spring belt rubber head is pushed out by the fastening needle push assembly 44. The fastening needle 43 returns along the original path.

[0064] Step S7 represents the loop and leak detection: In the specific operation process, steps S5 to S6 are repeated until the buckling operation of all points in the current row is completed; then a leak detection is performed. Specifically, the leak detection module 54 marks the unsuccessful points and provides a prompt to re-mark the unsuccessful points, and then the process is repeated in the next row until the buckling operation of all rows is completed.

[0065] Example 10: In step S4, the point matrix editing area supports preset buckle arrangement patterns of various specifications. Each specification is identified by name and associated with a set of default process parameters. Users can load the corresponding buckle point configuration and process parameters by selecting a name.

[0066] Specifically, the point matrix editing area 531 supports preset buckle arrangement patterns of various specifications. Each specification is identified by name and associated with a set of default process parameters. Users can load the corresponding buckle point configuration and process parameters with one click by selecting the name.

[0067] When switching product specifications, operators can select the corresponding specification name through a drop-down menu, and the point arrangement and process parameters of that specification will be automatically loaded. This eliminates the need for reconfiguration point by point, shortening changeover time and improving operational efficiency in multi-variety, small-batch production modes.

[0068] The following are optional embodiments of this application, used to further optimize the above technical solution. The optional embodiments can be implemented individually or in combination with each other: In one alternative embodiment, embodiment 11: the fastening actuator includes at least two fastening pins arranged side by side in a horizontal direction, each fastening pin being driven by an independent fastening pin pushing component; The control system is configured to control each threading pin to perform threading action according to a preset synchronous or asynchronous mode. The synchronous mode is used for simultaneous threading at adjacent points in the same row, while the asynchronous mode is used for time-sharing threading to avoid the spring nodes inside the mattress.

[0069] In this application, the mattress's internal spring core consists of multiple rows of springs. If the fastening point coincides with a spring node (i.e., the spiral position of the spring wire), the resistance during needle penetration increases sharply, easily leading to needle breakage, jamming, or failure to release the rubber tip. By employing a multi-needle synchronous / asynchronous mode: when the fastening point is located in the gap between adjacent springs, each fastening needle enters synchronously, completing fastening at adjacent points in the same row simultaneously, improving efficiency; when the fastening point may coincide with a spring node, each fastening needle enters asynchronously in a preset order, and the timing is staggered based on the relative relationship between the fastening position and the spring arrangement, ensuring that each fastening needle penetrates at a position avoiding spring nodes. Compared to existing fixed-arrangement mattress fastening devices, this optional embodiment can dynamically adjust the fastening sequence according to the internal structure of the spring core, improving fastening efficiency, effectively reducing the probability of needle breakage and jamming, and ensuring consistent fastening quality.

[0070] In one alternative embodiment, Example 12: In this application, the needle tip cone angle of the buttoning needle is 15° to 30°; The depth of the slot is 60% to 80% of the length of the spring with rubber head; The push-out stroke of the inner push component is 1.2 to 1.5 times the groove depth to ensure that the spring-loaded rubber head is fully pushed out and the inner push component does not exceed the end face of the needle bar.

[0071] In this application, the needle tip cone angle is limited to the range of 15° to 30°: if the cone angle is too small, the needle tip strength is insufficient and it is easy to bend; if the cone angle is too large, the puncture resistance increases significantly and it is difficult to penetrate multiple layers of materials. The groove depth is limited to 60% to 80% of the length of the spring-loaded rubber head: if the depth is too shallow, the rubber head is easy to fall off during the penetration process; if the depth is too deep, the rubber head is difficult to be pushed out smoothly. The push-out stroke of the inner push component is limited to 1.2 to 1.5 times the groove depth: if the stroke is insufficient, the rubber head cannot completely detach from the groove; if the stroke is too large, the inner push component will exceed the end face of the needle bar and may damage the mattress surface. The above parameters are interrelated and mutually constrained, forming a set of synergistically optimized structural parameters that ensure smooth puncture while achieving complete release of the rubber head, taking into account the reliability of the fastening, the positioning accuracy of the rubber head, and the protection of the mattress surface.

[0072] In an alternative embodiment, Example 13, this application uses segmented control of clamping pressure: The output pressure P of the clamping cylinder and the mattress thickness t detected by the thickness detection sensor satisfy the following relationship: ;in; k is the pressure coefficient determined based on the mattress's elastic modulus. The base preload is used; the output pressure range of the clamping cylinder is 0.3MPa to 0.8MPa. When the thickness value t is less than 50mm, the output pressure is set to the lower limit of 0.3MPa to avoid excessive compression and damage to the internal spring structure of the mattress. When the thickness value t is greater than 120mm, the output pressure is set to the upper limit of 0.8MPa, ensuring reliable clamping.

[0073] In this application, the mattress is a flexible multi-layered heterogeneous material. When the thickness is clamped, it is a non-linear compression. At this time, if a constant clamping force is applied, the thin mattress is prone to excessive compression that damages the internal spring structure, while the thick mattress will have insufficient clamping force, resulting in mattress displacement when the buckle is fastened.

[0074] This optional embodiment establishes a linear calibration relationship between clamping pressure P and thickness value t. (k is calibrated based on the mattress's elastic modulus), and a pressure limit and segmented strategy are set from 0.3MPa to 0.8MPa: for thin mattresses (t<50mm), the lower pressure limit is 0.3MPa to avoid excessive compression and damage to the spring structure; for thick mattresses (t>120mm), the upper pressure limit is 0.8MPa to ensure reliable clamping; the intermediate thickness range is adaptively adjusted according to a linear relationship. Through segmented pressure control, precise matching of clamping force for mattresses of different specifications is achieved, which not only protects the internal structure of the mattress but also ensures that the mattress is firmly fixed when the buckle is inserted, effectively solving the technical problems of uneven clamping force and poor penetration accuracy caused by non-linear compression of the mattress.

[0075] In an optional embodiment, embodiment 14, the fastening actuator of this application further includes a fastening force sensor. The fastening force sensor is disposed on the force transmission path between the fastening needle push assembly and the fastening needle, and is used to detect the axial resistance during the fastening process in real time. When the axial resistance exceeds the preset resistance threshold and continues for more than the preset time, it is determined that the fastening needle has encountered an impenetrable obstacle. The control system controls the fastening actuator to stop the needle advance and reverse back, and at the same time displays the needle jamming alarm information on the human-machine interface.

[0076] In this application, the mattress may contain impenetrable obstacles such as metal foreign objects, hard labels, and spring nodes. If the fastening needle attempts to penetrate, it is highly likely to break or damage the mattress. A fastening force sensor monitors the axial resistance of the fastening in real time. When the resistance exceeds a preset threshold and persists for a preset duration, it is considered an impenetrable obstacle, eliminating any possibility of momentary impact interference. The system immediately stops advancing the needle and reverses its direction, simultaneously displaying a stuck needle alarm on the interface to prompt the operator to check and handle the situation. This protection mechanism effectively avoids needle breakage accidents, reduces equipment failure rates, and improves equipment operational safety.

[0077] In one optional embodiment, Example 15: The thickness detection sensor performs accurate thickness detection through a limiting device. The limiting device is provided with a maximum limiting point and a minimum limiting point, and a fastening point is provided between the maximum limiting point and the minimum limiting point.

[0078] In this application, the limiting device 35 is provided with a maximum limiting point 351 and a minimum limiting point 352, and a fastening point 353 is provided between the maximum limiting point 351 and the minimum limiting point 352. By constraining the detection range of the mattress thickness through the maximum / minimum limiting points and setting the fastening point position between them, the thickness detection and the fastening positioning reference are consistent, which improves the accuracy of thickness detection and fastening point position calculation and avoids positioning deviation caused by the drift of the detection reference.

[0079] In one optional embodiment, Example 16: the flipping drive is a servo motor, and the flipping angular velocity of the flipping frame is 0.5° / s to 3° / s; wherein, the lower limit of 0.5° / s is used to prevent the mattress from slipping due to inertia during the flipping process, and the upper limit of 3° / s is used to achieve rapid flipping while ensuring the stability of the mattress. The range of 0.5° / s to 3° / s is determined by dynamic simulation based on the weight of the mattress and the friction coefficient of the flipping frame surface.

[0080] In this application, excessive angular velocity during the flipping process can cause the mattress to slip or even fall due to inertia, while insufficient angular velocity reduces production efficiency. Through dynamic simulation, an angular velocity range of 0.5° / s to 3° / s was determined based on the mattress weight and the coefficient of friction of the flipping frame surface: a lower limit of 0.5° / s avoids inertial slippage, while an upper limit of 3° / s ensures rapid flipping while maintaining stability, thus balancing flipping safety and production efficiency.

[0081] In one optional embodiment, embodiment 17: A point matrix editing area consisting of multiple rows and columns of circular icons from L1 to Ln is displayed in the human-computer interaction interface; in response to the user's click operation on the circular icons, the corresponding point is switched between the selected state and the unselected state, and the selected point is marked with a first color and the unselected point is marked with a second color; the process parameters input by the user are received, including at least the thickness selection value, the interval length value and the bottom edge distance value; based on the row and column positions of the selected points and the process parameters, the X-axis coordinates and Z-axis coordinates of each point are automatically calculated to generate the target motion sequence of the fastening actuator.

[0082] In this application, after the user selects the fastening points by clicking on the point matrix and inputs process parameters such as thickness selection, interval length, and bottom edge distance, the system automatically calculates the X-axis and Z-axis coordinates of each fastening point based on the row and column positions of the selected points and the process parameters, generating the target motion sequence of the fastening actuator 4. For example, the bottom edge distance is used to determine the Z-coordinate reference of the bottom row of fastening points, the interval length is used to determine the X-coordinate spacing between adjacent points in the same row, and the thickness selection is used to determine the needle insertion depth reference of the fastening needle. In this way, the graphical point selection is automatically converted into an executable CNC motion instruction sequence, eliminating the need for manual measurement of coordinates point by point. This ensures the consistency of point coordinate calculation and simplifies the programming process of the fastening scheme.

[0083] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. An automatic mattress positioning and fastening machine, characterized in that, include: Rack (1); A flipping mechanism (2) is provided on the frame (1) for flipping a mattress lying flat on the workbench to an upright position; The clamping mechanism (3) includes an upper clamping assembly (31) and a lower clamping assembly (32) arranged opposite to each other, and a thickness detection sensor for detecting the thickness of the mattress. The detection signal of the thickness detection sensor is used to control the clamping distance between the upper clamping assembly (31) and the lower clamping assembly (32). The fastening actuator (4) includes a fastening pin (43) and a fastening pin pushing assembly (44). The head of the fastening pin (43) is provided with a slot (431) for accommodating the spring-loaded rubber head (432). The fastening pin pushing assembly (44) is used to push out the spring-loaded rubber head (432) in the slot (431) and make the fastening pin (43) return along the original path.

2. The automatic mattress positioning and fastening machine according to claim 1, characterized in that, The flipping mechanism (2) includes a flipping drive motor and a flipping frame. The flipping frame can rotate around a horizontal axis, so that the mattress placed on it can switch between a horizontal posture and an upright posture. The flipping angle of the flipping mechanism ranges from 0° to 90°.

3. The automatic mattress positioning and fastening machine according to claim 1, characterized in that: The upper clamping assembly (31) and the lower clamping assembly (32) respectively include a clamping cylinder (11) and a clamping bar (33); The thickness detection sensor is disposed on one side of the lower clamping assembly (32) and is used to detect the thickness value of the mattress placed between the upper clamping assembly (31) and the lower clamping assembly (32); The clamping cylinder (11) adaptively adjusts the clamping stroke according to the thickness value.

4. The automatic mattress positioning and fastening machine according to claim 1, characterized in that, The fastening actuator (4) further includes an inward pushing component (46), which is located at the tail of the fastening needle (43) and is used to push the spring belt rubber head out of the slot after the fastening needle (43) penetrates the mattress. The button-feeding push assembly is connected to the inner push component (46) for transmission. After the inner push component (46) completes the pushing action, the button-feeding needle (43) is driven to retract in the opposite direction along the needle insertion path.

5. An automatic control system for controlling the automatic mattress positioning and fastening machine according to any one of claims 1 to 4, characterized in that, The system includes: The numerical control positioning module includes an X-axis motion mechanism and a Z-axis motion module, which are used to control the buckle actuator (4) to adjust its position in the horizontal and vertical directions; Human-computer interaction module, wherein the human-computer interaction module is provided with a coordinate display submodule and a coordinate calibration zeroing submodule human-computer interaction interface; A visual programming module is set in the human-computer interaction interface, including a point matrix editing area. The point matrix editing area displays a configuration array of multiple rows and columns of buckle points in a graphical manner from L1 to Ln. It supports users to select or edit the arrangement of buckle positions by clicking on the points, and supports the configuration of process parameters, which include at least thickness selection, interval length and bottom edge distance.

6. The automatic control system according to claim 5, characterized in that: The X-axis motion mechanism includes an X-axis drive unit and an X-axis guide assembly, which are used to drive the buckle actuator (4) to move in the left and right directions to align with the clamping gap of the frame (1); The Z-axis motion module includes a Z-axis drive unit and a Z-axis guide assembly, which are used to drive the buckle actuator (4) to move in the up and down direction to the corresponding pin height position; The coordinate calibration and zeroing module includes an X-axis calibration button and a Z-axis zeroing button.

7. The automatic control system according to claim 5, characterized in that: The number of rows n in the point matrix editing area is an integer from 6 to 12; each point in the point matrix editing area is represented by a circular icon, selected points are marked with a first color, and unselected points are marked with a second color; The process parameters also include the current serial number parameter and the real-time display parameter of the pin position.

8. The automatic control system according to claim 5, characterized in that, The system also includes a leak detection module, which is communicatively connected to the human-machine interface. The leak detection module is used to detect holes that have not successfully passed through the spring belt after a row of buckle-fastening actions are completed, and to display a warning in a third color at the corresponding point in the point matrix editing area.

9. The automatic control system according to claim 5, characterized in that, The numerical control positioning module performs the following steps: S1. The mattress is transported to the fastening station and laid flat. The clamping mechanism is activated to compress and clamp the two sides of the mattress. At the same time, the thickness data of the mattress is obtained by the thickness detection sensor and the clamping amount is adjusted according to the thickness data. S2. Control the flipping mechanism to flip the mattress from a horizontal position to an upright position; S3. Perform coordinate calibration operation. Adjust the horizontal position of the fastening actuator through the X-axis motion mechanism so that the fastening pin is aligned with the gap of the frame clamping rod. Perform X-axis calibration and Z-axis zeroing operation. S4. In the point matrix editing area of ​​the human-computer interaction interface, select the desired buckle arrangement pattern and process parameters, including thickness selection, interval length and bottom edge distance; S5. Based on the selected fastening point, control the CNC positioning module to drive the fastening actuator to move to the corresponding pin position height; S6. Control the fastening actuator to perform the fastening action. The fastening needle carries the spring belt through the mattress, and then the spring belt rubber head is pushed out by the fastening needle push component. The fastening needle returns along the original path. S7. Repeat steps S5-S6 until the buckle operation of all points in the current row is completed, perform a leak detection and prompt for unsuccessful points to be re-attached.

10. The automatic control system according to claim 9, characterized in that, In step S4, the point matrix editing area presets various specifications of buckle arrangement patterns, and the buckle arrangement patterns are identified by name and associated with a set of default process parameters; When any name identifier is selected and triggered by the user, the corresponding buckle point configuration and process parameters are loaded.

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