A compound assembly line for pasting cotton felt and four-edge sealing sponge strip on a mattress

Abstract

The embodiment of the present application provides a composite assembly line for pasting bottom cotton felt, bed core and top cotton felt and sealing sponge strips on four edges, comprising: an inclined conveyor for receiving bottom cotton felt, bed core and top cotton felt sent by a front-end glue spraying process and performing horizontal conveying or pneumatic inclined conveying according to a process beat; a double-layer inclined conveyor located at an output end of the inclined conveyor, used for receiving the bed core and the top cotton felt conveyed by the inclined conveyor and conveying the bed core and the top cotton felt to above a designated assembly position by a top-layer conveying mechanism of the double-layer inclined conveyor to cooperate with downward placing; and a composite assembly table located at an adjacent position below a conveying end of the double-layer inclined conveyor, used for automatically adjusting and forming an assembly reference frame according to a set mattress size to receive the bottom cotton felt, position the sponge strips around and receive the bed core and the top cotton felt placed from the double-layer inclined conveyor to perform six-surface composite pasting.

Description

Technical Field

[0001] This invention relates to the field of automatic mattress processing technology, and in particular to a composite assembly line for attaching upper cotton felt and four-sided sealing foam strips to a mattress. Background Technology

[0002] During mattress manufacturing, top and bottom felts need to be applied and the edges sealed with foam strips to ensure six-sided comfort. Applying the top and bottom felts and sealing the edges with foam strips must be done separately. Currently, the application of the top and bottom felts requires large equipment such as robotic arms and turntables for manual assistance in moving and flipping them. Furthermore, workers manually flip and apply the top and bottom felts during the application process. Similarly, sealing the edges with foam strips also requires multiple workers working together with the help of a turntable. In practice, manual adjustment of the felt and foam strip positions is prone to misalignment, resulting in inaccurate length and width dimensions, diagonal discrepancies, and a defect rate of approximately 5%-8%. Workers need to flip and move mattresses weighing 20-40kg, and long-term operation can easily lead to physical discomfort for workers. It can be seen that the root cause of the above problems is the lack of automatic positioning and the dispersion of processes. Therefore, when processing mattresses, there is a lack of a mattress composite assembly line that can solve the technical problems of manual turntable operation, which still requires moving and flipping, resulting in low efficiency, inaccurate finished product dimensions, or excessively long automatic lines. Summary of the Invention

[0003] This invention provides a composite assembly line for attaching top and bottom cotton felt and four-sided sealing foam strips to a mattress, which solves the technical problems of manual operation using a turntable in mattress manufacturing, which requires moving and flipping, resulting in low efficiency, inaccurate finished product dimensions, or excessively long automated lines.

[0004] This invention provides a composite assembly line for attaching top and bottom cotton felts and four-sided sealing foam strips to a mattress, comprising: a slanted conveyor for receiving the bottom cotton felt, mattress core, and top cotton felt from the front-end adhesive spraying process, and conveying them horizontally or pneumatically according to the process rhythm; a double-layer slanted conveyor located at the output end of the slanted conveyor for receiving the mattress core and top cotton felt conveyed by the slanted conveyor, and conveying the mattress core and top cotton felt to a designated assembly position above it through its top layer conveying mechanism, so as to cooperate with the mattress core in being lowered; and a composite assembly table located below and adjacent to the conveying end of the double-layer slanted conveyor for automatically adjusting according to the set mattress size and forming an assembly reference frame to receive the bottom cotton felt, position the four-sided foam strips, and receive the mattress core and top cotton felt lowered from the double-layer slanted conveyor for six-sided composite bonding.

[0005] This invention also provides a mattress assembly method using a composite assembly line for attaching top and bottom cotton felt and four-sided sealing foam strips, comprising the following steps: S1, setting the required mattress size, the left and right reference rods of the composite assembly table automatically move to the specified size position in conjunction with the bakelite tabletop, and the rear reference pneumatic lifting mechanism and servo fixed-length pneumatic lifting mechanism raise the front and rear reference rods; S2, after the bottom cotton felt has undergone a spray adhesive process, it is horizontally conveyed from the inclined conveyor to the tabletop of the composite assembly table; S3, the reference rods are reset, and the operator places the four-sided foam strips along the left and right reference rods of the composite assembly table, and so on. S4. The mattress core is pneumatically conveyed to the upper layer of the double-layer inclined conveyor via an inclined conveyor. The top layer of the double-layer inclined conveyor is then conveyed and pneumatically lowered. Once it reaches the designated position, the foot switch is triggered, and the top layer conveyor belt safely and slowly retracts, placing the mattress core in the center of the composite assembly table. S5. The top cotton felt is sprayed with adhesive and reaches the inclined conveyor's slope position. After the top layer conveyor belt retracts, the top cotton felt is conveyed to the rear reference position and, under guidance, is applied. S6. After the top cotton felt is applied, the switch is turned on to raise the front and rear reference rods, and the applied mattress is conveyed to the next pressing process.

[0006] The working principle and beneficial effects of this invention are as follows: This invention is used to attach cotton felt to the bottom and top surfaces of a mattress, as well as sponge strips to the left, right, front, and back. In the process steps of this invention, the preceding process connects to the adhesive spraying part, and the subsequent process connects to the pressing part. Using the assembly line provided by this invention for mattress assembly is more convenient and faster than the traditional method of manually rotating and pasting using a turntable. The equipment also occupies less space, and two people can complete the neat pasting of all six sides of the mattress. Furthermore, because the composite assembly table controls the different dimensions of the mattress, the accuracy of the assembly dimensions is higher. The specific process of this invention includes: first, setting the size of the mattress to be made; the composite assembly table automatically positioning itself at the designated size; the bottom cotton felt being conveyed to the surface of the composite assembly table via a spray adhesive process; two workers each placing the surrounding sponge strips against the reference rods of the composite assembly table; simultaneously, the mattress core being conveyed to the upper layer of the double-layer inclined conveyor; the two workers jointly activating the switch, which starts the top layer conveyor of the double-layer inclined conveyor; at the same time, the top layer conveyor end pneumatically descends, making it easier for the workers to place the mattress core; after reaching the designated position, the two workers gently hold the front end of the mattress core and jointly step on the foot pedal switch, which safely and slowly retracts the top layer conveyor, allowing the workers to place the mattress core neatly in the center of the assembly table; the top cotton felt is simultaneously sprayed with adhesive; upon reaching the inclined conveyor position, waiting for the top layer conveyor to retract into place, the top cotton felt is conveyed to the designated position; the workers assist in guiding the position to attach the top cotton felt while the top layer is conveyed into place; after attaching the top cotton felt, the workers simultaneously turn on the switch to raise the front and rear reference rods, and the attached mattress proceeds to the next pressing process.

[0007] 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.

[0008] 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

[0009] 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 of the structure of the present invention; Figure 2 This is a schematic diagram of the inclined conveyor structure of the present invention; Figure 3 This is a schematic diagram of the double-layer inclined conveyor structure of the present invention; Figure 4 This is a schematic diagram of the collision stopping mechanism of the present invention; Figure 5 This is a schematic diagram of the composite assembly platform structure of the present invention; Figure 6 This is a schematic diagram of the rear reference pneumatic lifting mechanism of the present invention; Figure 7 This is a schematic diagram of the left and right servo opening and closing mechanism of the present invention; Figure 8 This is a schematic diagram of the servo-driven fixed-length pneumatic lifting mechanism of the present invention; Figure 9 This is a schematic diagram of the belt conveyor mechanism and servo linkage table structure of the present invention; Figure 10 This is a schematic diagram of the linkage positioning part of the present invention; Figure 11 This is a schematic diagram of the linkage sensing sensor structure of the present invention; Figure 12 This is a schematic diagram of the linkage track structure of the present invention.

[0010] Among them, 1- Inclined conveyor, 2- Double-layer inclined conveyor, 3- Composite assembly table, 4- Conveying platform, 5- Inclined lifting mechanism, 6- Frame, 7- Horizontal conveyor belt, 8- Top layer conveyor belt, 9- Conveying pneumatic lifting mechanism, 10- Safety sheet metal cover, 11- Safety limit switch, 12- Fixing plate, 13- Fixing plate, 14- Reset plate, 15- Rear reference pneumatic lifting mechanism, 16- Servo fixed-length pneumatic lifting mechanism, 17- Left and right servo opening and closing mechanism, 18- Servo linkage table, 19- Belt conveyor mechanism, 20- Side plate, 21- Pneumatic lifting mechanism, 22- Connecting rod, 23- Rear reference rod. 24-Horizontal bar, 25-Left and right reference bars, 26-Linear guide rail, 27-Linkage power rod, 28-Synchronous belt drive structure, 29-Linkage table pneumatic positioning point, 30-Front reference bar, 32-Control switch, 33-Linear guide rail rack and pinion servo transmission mechanism, 34-Pulley, 35-Motor, 36-Upright plate, 37-Induction reference plate, 38-Assembly hole, 39-Assembly seat, 40-Pneumatic positioning device, 41-Angle iron, 42-Side upright, 43-Longitudinal connecting rod, 44-Induction connecting plate, 45-Linkage induction sensor, 46-Linkage guide rail, 47-Linkage rod, 48-Linkage track. Detailed Implementation

[0011] 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.

[0012] according to Figures 1-12 As shown, this embodiment of the invention provides a composite assembly line for attaching top and bottom cotton felts and four-sided sealing sponge strips to a mattress, including: a slanted conveyor 1, used to receive the bottom cotton felt, mattress core and top cotton felt sent out by the front-end glue spraying process, and to perform horizontal conveying or pneumatic slanted conveying according to the process rhythm. The double-layer inclined conveyor 2 is located at the output end of the inclined conveyor 1. It is used to receive the bed core and top cotton felt conveyed by the inclined conveyor 1, and to convey the bed core and top cotton felt to the designated assembly position through its top layer conveying mechanism 8, so as to cooperate with the bed core for lowering. The composite assembly table 3 is located below and adjacent to the conveying end of the double-layer inclined conveyor 2. It is used to automatically adjust and form an assembly reference frame according to the set mattress size, so as to support the bottom cotton felt, position the surrounding sponge strips, and support the mattress core and top cotton felt put down from the double-layer inclined conveyor 2 for six-sided composite bonding.

[0013] In this invention, materials are input into the assembly line via an inclined conveyor 1, and a double-layer inclined conveyor 2 enables spatial layered flow of materials. A horizontal conveyor belt 7 transports the bottom layer materials, while a top layer conveyor mechanism 8 transports the heavier core and top layer materials, suspending them at the upper workstation for waiting. After acquiring dimensional parameters, the composite assembly table 3 performs linear displacement to form a physical positioning frame of corresponding dimensions, sequentially completing the receiving of the bottom layer materials, the positioning and laying of the surrounding sponge strips, and the receiving and alignment of the upper core at the same vertical workstation. The inclined conveyor 1 includes a conveying platform 4 and a ramp lifting mechanism 5 for adjusting the inclination of the conveying platform 4. The conveying platform 4 is mounted above a frame 6, and the ramp lifting mechanism 5 is located below the conveying platform 4. Through the coordinated operation of logistics and processes, the inclined conveyor 1 serves as the front-end material input, the double-layer inclined conveyor 2 achieves three-dimensional layered conveying and suspension buffering of materials, and the composite assembly table 3 serves as the end-effector. The three work together to achieve continuous mechanical movement of materials from input to finished output. Simultaneously, this invention integrates the conveying and assembly processes of the bottom, sides, and top of the mattress, reducing the material turnover rate between different workstations and the equipment footprint. It achieves vertical coordination between the pre-assembled frame and the lowering of materials from above, reducing manual intervention and improving the dimensional accuracy of the six-sided mattress bonding and the overall assembly line efficiency. Furthermore, by integrating multiple discrete processes into a single production line, the automatic positioning and conveying of machines replaces heavy manual handling, improving the overall assembly efficiency of the six-sided mattress bonding.

[0014] In one embodiment, the composite assembly platform 3 includes a bakelite tabletop, left and right reference rods 25, a rear reference pneumatic lifting mechanism 15, and a servo-controlled fixed-length pneumatic lifting mechanism 16; the left and right reference rods 25 are linked to the bakelite tabletop and automatically move into position according to the set mattress size; the rear reference pneumatic lifting mechanism 15 and the servo-controlled fixed-length pneumatic lifting mechanism 16 are used to control the lifting of the front reference rod 30, the rear reference rod 23, and the left and right reference rods 25 to form a foam assembly frame.

[0015] In this embodiment, the rear reference pneumatic lifting mechanism 15 and the servo-guided fixed-length pneumatic lifting mechanism 16 are used to control the vertical lifting of each reference rod (front reference rod 30, rear reference rod 23, and left and right reference rods 25). The mechanical linkage between the left and right reference rods 25 and the bakelite tabletop is used to adjust the physical width of the tabletop, thereby automatically forming a rigid rectangular frame according to the input mattress size parameters. Specifically, after receiving the preset mattress size signal, the composite assembly table 3 controls the left and right reference rods 25 to perform lateral horizontal displacement on the flat bakelite tabletop to determine the width limit. At the same time, the servo-guided fixed-length pneumatic lifting mechanism 16 moves longitudinally to the target length coordinate. After reaching the designated position, the pneumatic actuators inside the rear reference pneumatic lifting mechanism 15 and the servo-guided fixed-length pneumatic lifting mechanism 16 output power to drive the corresponding front reference rod 30, rear reference rod 23, and left and right reference rods 25 to perform vertical lifting. The four raised front reference rods 30, rear reference rod 23, and left and right reference rods 25, together with the bakelite tabletop, form a rectangular positioning frame that fixes the mattress size.

[0016] This invention replaces manual positioning with a rectangular positioning frame that fixes the size of the mattress, ensuring uniform size and positioning accuracy when assembling the surrounding foam strips; it also enables automated adjustment of the assembly table boundary size, allowing for rapid adaptation to the production needs of mattresses of different specifications.

[0017] In one embodiment, the composite assembly table 3 includes a servo-linked table surface 18 and a belt conveyor mechanism 19 disposed on the table surface; the left and right reference rods 25 are driven by a left and right servo opening and closing mechanism 17, which includes a linear guide rail 26, a linkage power rod 27 and a synchronous belt drive structure 28, for driving the left and right reference rods 25 to move in opposite directions or backwards to adjust the width reference of the mattress. The rear reference pneumatic lifting mechanism 15 includes a vertically arranged pneumatic lifting mechanism 21. The power output end of the pneumatic lifting mechanism 21 is connected to the rear reference rod 23 and is used to control the raising and lowering of the rear reference rod 23. The servo fixed-length pneumatic lifting mechanism 16 includes a front reference rod 30, and a linear guide rack servo transmission mechanism 33 driven by a motor 35 moves and positions itself in the length direction to adapt to different mattress lengths; the front reference rod 30, the rear reference rod 23, and the left and right reference rods 25 together form the sponge assembly frame after being raised.

[0018] In this embodiment, the pneumatic lifting mechanism 21 is mounted on the column via a side plate 20. A crossbar 24 for connecting the longitudinal connecting rod 43 is provided on the other side of the column. The output end of the pneumatic lifting mechanism 21 is connected to the rear reference rod 23 via a connecting rod 22.

[0019] Motor 35 drives the linear guide rail 26, rack 33, and synchronous belt drive structure 28, providing linear displacement drive for each reference rod (front reference rod 30, rear reference rod 23, left and right reference rods 25) in the horizontal and vertical directions, achieving precise adjustment of the length and width dimensions of the assembly frame. Width adjustment is achieved by servo motor 35 driving synchronous belt drive structure 28, with linkage power rod 27 pulling left and right reference rods 25 to slide horizontally in opposite or opposite directions on linear guide rail 26. Length adjustment is powered by another set of motors 35, which, through the mechanical meshing of gears and rack 33, drive the mechanism with front reference rod 30 to move longitudinally along linear guide rail 26. After the length and width positions are calibrated, the vertically arranged cylinder extension rod pushes the front reference rod 30 and rear reference rod 23 to complete the lifting and lowering.

[0020] In this embodiment, a servo motor 35 is used in conjunction with a linear guide rail 26 and a synchronous belt drive structure 28 and a rack and pinion 33 to effectively reduce the mechanical cumulative error caused by transmission gaps, and improve the smoothness and positioning accuracy of the front reference rod 30, rear reference rod 23, and left and right reference rods 25 during the adjustment process; this ensures that the diagonal size tolerance of the assembled frame is controlled within a controllable range (the diagonal accuracy of the assembled mattress is ≤ ±0.5mm), thereby improving the uniformity of the final mattress appearance.

[0021] In one embodiment, the side of the servo linkage table 18 is also provided with a pneumatic positioning device 40 and a linkage sensing mechanism to perform positioning and locking after the table size is adjusted. The linkage sensing mechanism includes a vertical plate 36, a sensing reference plate 37 disposed on the vertical plate 36, a sensing connection plate 44, and a linkage sensing sensor 45. The pneumatic positioning device 40 is fixed by angle iron 41 and provides a support structure in conjunction with the longitudinal connecting rod 43; the induction connecting plate 44 is provided with an assembly hole 38, and a linkage induction sensor 45 is installed on the assembly hole 38; the power output end of the pneumatic positioning device 40 is set in accordance with the assembly hole 38, and is used for pneumatic pin positioning after the table is adjusted to the position. The edge of the servo linkage platform 18 is also provided with a side stand 42, and its bottom is equipped with a linkage guide rail 46, a linkage rod 47 and a linkage track 48, so as to cooperate with the linkage sensing sensor 45 to realize position signal feedback and smooth guidance during the sliding process.

[0022] In this embodiment, after the servo mechanism completes the initial position adjustment of the table, the linkage sensing sensor 45 confirms the position coordinates, and then the power output end of the pneumatic positioning device 40 pops out and is precisely inserted into the assembly hole 38 of the sensing connection plate 44 to achieve physical pin-type locking.

[0023] The pneumatic positioning device 40 and the linkage sensing mechanism form pneumatic positioning points 29 on the linkage table, with at least four sets located at both ends of the left and right reference rods 25. The servo-driven fixed-length pneumatic lifting mechanism is also equipped with pulleys 34, facilitating the transfer or adjustment of the overall composite assembly table 3. The pneumatic positioning device 40 has a top plate 39 at one end of the angle iron 41. When the servo-driven linkage table 18 slides on the linkage rail 48, the linkage sensing sensor 45 continuously detects the displacement coordinates and feeds back electrical signals. When the control system determines that the table has reached the target position, it stops the power output of the servo drive unit and triggers the solenoid valve of the pneumatic positioning device 40.

[0024] The power output rod of the pneumatic positioning device 40 extends and precisely inserts into the corresponding mounting hole 38 of the induction connecting plate 44, forming mechanical interference and thus locking the movable table to the fixed frame. This embodiment combines the flexible position detection of the sensor with the rigid physical locking of the pneumatic pin, which eliminates the slight yielding and mechanical vibration that the servo motor 35 may produce under pressure, enhances the structural rigidity of the table when bearing the weight of the bed core above and the lateral sponge pressing force, and prevents dimensional deviation during operation.

[0025] In one embodiment, the top conveying end of the double-layer inclined conveyor 2 is provided with a pneumatic lifting mechanism 9; the top conveying end can be pneumatically lowered when the top conveying is started, so as to reduce the height difference for receiving and placing the bed core.

[0026] In this embodiment, after the mattress core reaches the designated assembly position, the pneumatic lifting mechanism 9 drives the top conveyor end to move vertically downwards, shortening the height difference between the top conveyor belt 8 and the lower composite assembly platform 3. Specifically, the top cotton felt and mattress core are horizontally conveyed to the end position of the top conveyor end. When the system receives a lowering command, the cylinder of the pneumatic lifting mechanism 9 retracts, causing the output end structure of the top conveyor belt 8 to move vertically downwards, thereby shortening the vertical height difference between the end of the top conveyor mechanism 8 and the receiving surface of the lower composite assembly platform 3. By actively shortening the height difference between the equipment, the load and labor intensity of the operator when receiving a heavy mattress core are significantly reduced; material deformation or edge damage caused by gravity during the long-distance lowering of the mattress core is avoided; and the human-machine interaction working environment is improved.

[0027] In one embodiment, the top conveying end of the double-layer inclined conveyor 2 is also provided with a collision stop mechanism and a spring reset mechanism 12; when an operator or object touches the collision stop mechanism, the top conveyor belt 8 and the conveying pneumatic lifting mechanism 9 are triggered to stop; when the contact stops, the spring reset mechanism 12 resets the mechanism, and the mechanism resumes operation after the switch 32 is restarted.

[0028] In this embodiment, when a foreign object or human body abnormally touches the collision stop mechanism, the mechanism undergoes mechanical displacement, changing its switch state. Upon receiving the signal, the system cuts off the pneumatic and electric circuits, causing the equipment to hover. After the danger is eliminated, the mechanical elasticity of the spring reset mechanism 12 returns it to its original position. Specifically, during the descent or conveying action of the top conveyor belt 8, if an external object exerts compressive stress on the collision stop mechanism, this stress overcomes the elastic potential energy of the spring reset mechanism 12, causing the mechanism to displace inward. This displacement triggers the internal limit switch 11, generating a change in electrical signal. Upon recognizing this signal, the control system immediately cuts off the drive circuit between the conveyor mechanism 8 and the pneumatic lifting mechanism 9. After the external stress is relieved, the spring reset mechanism 12 releases its elastic potential energy, returning the mechanism to its initial position. The system resumes operation after receiving a restart signal.

[0029] In this embodiment, by setting up anti-pinch and anti-collision protection functions, power can still be cut off by hardware even if the control system experiences logical lag, ensuring worker safety. Specifically, in the event of accidental obstruction or contact, the mechanical action output of the equipment can be quickly interrupted to avoid personnel injury or equipment damage caused by the forced operation of the drive mechanism.

[0030] In one embodiment, the double-layer inclined conveyor 2 is mounted on the frame 6 and includes a horizontal conveyor belt 7 at the lower layer and a top layer conveyor belt 8 at the upper layer; the bottom of the conveying end of the top layer conveyor belt 8 is connected to the conveying pneumatic lifting mechanism 9, which is used to adjust the height of the top layer conveyor belt 8; the collision stop mechanism is located on the outer side of the end of the top layer conveyor belt 8, and the collision stop mechanism includes a safety limit switch 11 located on one side of the spring reset mechanism 12; The spring reset mechanism includes a fixed plate 12, a guide post 13, and a reset plate 14. The fixed plate 12 is located on the outer side of the end of the top layer conveyor belt 8. The guide post 13 is located on the side of the fixed plate 12 away from the safety limit switch 11, and a spring is provided on the guide post 13. The spring is connected to the reset plate 14, and the reset plate 14 passes through the guide post 13 and reciprocates on the guide post 13 according to the working state of the spring. In the normal state, the spring reset mechanism 12 supports the reset plate 14 to protrude outward. When the reset plate 14 is impacted and squeezed inward, the spring reset mechanism 12 is compressed and the safety limit switch 11 is triggered, thereby controlling the top layer conveyor belt 8 to stop running and the conveyor pneumatic lifting mechanism 9 to stop descending.

[0031] In this embodiment, the reset plate 14 is covered with a safety sheet metal cover 10 to protect it from damage. The spring reset mechanism 12 is formed by the fixed plate 12 and the reset plate 14, creating a buffer surface. When compressed, the safety limit switch 11 is triggered. During the dual-switch collaborative judgment process at the control end, signals from both the foot pedal and the start switch 32 must be received simultaneously before the conveying or slow retraction action is executed. Specifically, the fixed plate 12 is rigidly connected to the main body of the equipment, and the reset plate 14 serves as the load-bearing surface; the two are connected by the spring reset mechanism 12. Under normal conditions, the spring keeps the reset plate 14 in the extended state, and the safety limit switch 11 is installed in the gap behind the fixed plate 12 or the reset plate 14. When the front end of the reset plate 14 is compressed and undergoes a backward linear or tilting displacement, the plate compresses the spring and physically contacts the contact of the safety limit switch 11. The switch flips and closes, sending a hardware interrupt signal to the controller, which then cuts off the power unit.

[0032] In this embodiment, the plate-shaped reset plate 14 provides a large effective contact area. Combined with the buffering and supporting effect of the spring, it ensures that no matter where the force point is on the reset plate 14, it can be effectively converted into an inward displacement and accurately trigger the safety limit switch 11. This prevents the risk of accidental equipment operation caused by a single person accidentally touching the switch. The slow retraction action allows the bed core to fall smoothly into the assembly frame by its own weight, eliminating hard friction and achieving both efficient feeding and safety protection.

[0033] In one embodiment, a dual-person collaborative control system is also included. This control system is connected to a common start switch and a foot switch 32. The top layer conveying of the double-layer inclined conveyor 2 requires both sets of switches 32 to be triggered simultaneously, and the top layer conveying mechanism 8 is retracted or conveyed via the foot switch 32. In this embodiment, the main control board of the dual-person collaborative control system operates the signals of the two sets of start switches 32 located at different working positions on the equipment. It issues a descent command only when both sets of switches 32 are closed simultaneously within a specified time window.

[0034] After the bed core contacts the assembly table, both sets of foot switches 32 must simultaneously receive a closing signal. The main control board then outputs a low-frequency or reverse operation command, driving the top conveyor belt 8 to slowly reverse backward. By requiring operators to perform synchronized and coordinated actions, the risk of malfunctions caused by unilateral manual operation is limited, ensuring safety. Utilizing the reverse movement of the conveyor belt 8 in conjunction with the bed core's own gravity, a safe and slow retraction is achieved, allowing heavy materials to smoothly transition into the positioning frame and avoiding misalignment of the sponge strips or cotton felt caused by forced dragging.

[0035] This invention also provides a method for assembling a mattress using a composite assembly line for attaching top and bottom cotton felt and four-sided sealing foam strips, comprising the following steps: S1. Set the required mattress size. The left and right reference rods 25 of the composite assembly table 3 are linked to the bakelite tabletop to the specified size position. The rear reference pneumatic lifting mechanism 15 and the servo fixed length pneumatic lifting mechanism 16 raise the front reference rod 30 and the rear reference rod 23. S2. After the bottom cotton felt is sprayed with glue, it is horizontally conveyed from the inclined conveyor 1 to the table surface of the composite assembly table 3. S3, Reset the reference rod, place the surrounding sponge strips along the left and right reference rods 25 of the composite assembly table 3, and the bed core is conveyed to the upper layer of the double-layer inclined conveyor 2 via the inclined conveyor 1. S4. Trigger the start switch, the top layer of the double-layer inclined conveyor 2 will be conveyed and the top layer conveyor end will be pneumatically lowered. After reaching the designated position, trigger the foot switch, the top layer conveyor belt 8 will retract, and the bed core will be placed in the center of the composite assembly table 3. S5. The top cotton felt is sprayed with glue and reaches the inclined position of the inclined conveyor 1. After the top conveyor belt 8 is retracted, the top cotton felt is conveyed to the rear reference position and the top cotton felt is bonded. S6. After attaching the top cotton felt, turn on the switch to raise the front reference rod 30 and the rear reference rod 23, and transport the attached mattress to the next pressing process.

[0036] In this invention, the inclined conveyor 1 is used to receive the bottom cotton felt, bed core and top cotton felt sent from the front-end glue spraying process, and to convey them according to the current process position; the double-layer inclined conveyor 2 includes a lower horizontal conveyor belt 7 and an upper top layer conveyor belt 8, which are used to convey the bed core to the top of the composite assembly table 3 and cooperate with the conveying pneumatic lifting mechanism 9 to complete the bed core placement; the composite assembly table 3 includes a servo linkage table 18, a left and right servo opening and closing mechanism 17, a rear reference pneumatic lifting mechanism 15, a servo fixed length pneumatic lifting mechanism 16 and a belt conveyor mechanism 19, which are used to establish an assembly reference frame according to the size of the mattress to be assembled and to receive the mattress components.

[0037] This invention establishes an initial geometric reference for the entire assembly process, then completes the assembly of the bottom cotton felt and the surrounding sponge strips separately, and completes the transfer of the mattress core from the upper conveying mechanism to the composite assembly table 3. The state of the mattress core receiving the assembly is used as a mechanical prerequisite for the bonding of the top cotton felt. Finally, the assembly reference is released and the finished product is output. This invention realizes the sequential control of the inclined conveyor 1, the double-layer inclined conveyor 2, and the composite assembly table 3 according to the actual sequence of the mattress assembly process. The assembly reference state is used as the common geometric reference for the assembly process of the bottom cotton felt, the surrounding sponge strips, and the mattress core. The mattress core entering the allowable state is used as the mattress core conveying start condition, and the mattress core release state is used as the mechanical state condition for the top cotton felt conveying process.

[0038] The assembly of the mattress of the present invention includes: obtaining the length and width parameters of the mattress to be assembled; determining the target assembly size of the composite assembly platform 3 according to the length and width parameters; controlling the left and right servo opening and closing mechanism 17 to drive the left and right reference rods 25 to move to the corresponding width position; controlling the servo fixed length pneumatic lifting mechanism 16 to drive the front reference rod 30 to move to the corresponding length position; and controlling the rear reference pneumatic lifting mechanism 15 to drive the rear reference rod 23 into the working position to form an assembly reference frame. The bottom cotton felt, which has undergone the glue spraying process, is conveyed to the table surface of the composite assembly table 3 via the inclined conveyor 1, and the position of the bottom cotton felt is defined by the assembly reference frame; the left and right reference rods 25 are kept in the width positioning position, and the front reference rod 30 and the rear reference rod 23 are controlled to enter the sponge strip placement position, and the sponge strips around the four sides are placed according to the assembly reference frame; at the same time, the bed core is conveyed to the top conveyor belt 8 of the double-layer inclined conveyor 2 via the inclined conveyor 1. After the surrounding sponge strips are placed and the bed core conveying is allowed, control the top layer conveyor belt 8 to convey the bed core to the composite assembly table 3, and control the conveying pneumatic lifting mechanism 9 to lower the conveying end of the top layer conveyor belt 8 to the bed core receiving position; after the bed core reaches the receiving position, control the top layer conveyor belt 8 to run in reverse, so that the bed core is transferred to the composite assembly table 3 and enters the assembly reference frame. The top cotton felt, which has undergone the glue spraying process, is conveyed to the waiting position of the inclined conveyor 1. After the top conveyor belt 8 is detected to have completed its reverse retraction and the mattress core is in the receiving state of the composite assembly table 3, the inclined conveyor 1 is controlled to convey the top cotton felt to the corresponding bonding position. Under the positioning action of the assembly reference frame, the bonding of the top cotton felt and the mattress core is completed. After the top cotton felt is bonded, the front reference rod 30 and the rear reference rod 23 are controlled to descend, releasing the limitation of the assembly reference frame on the mattress. The mattress, which has completed the bonding of the upper and lower cotton felts and the four-sided sponge strips, is then conveyed to the next pressing process through the belt conveyor mechanism 19.

[0039] The composite assembly table 3 establishes the length and width benchmarks of the mattress based on servo positioning. The opening and limiting of the foam strip assembly area are achieved by raising and lowering the front and rear benchmark rods, and the finished product transfer is completed using the belt conveyor mechanism 19. Through unified assembly benchmarks and state control logic, the original inclined conveying, double-layer conveying, and composite assembly actions form a continuous process link, providing a unified control basis for subsequent benchmark error compensation, foam strip completion confirmation, dynamic core unloading, and top cotton felt time control. Simultaneously, this invention integrates the originally scattered material handling, edge positioning, and vertical bonding processes into a single control flow, allowing complex electromechanical coordination to form a standardized assembly line operation procedure. It rationally allocates the overlap between machine running time and manual assistance time, achieving continuous, non-stop assembly line operation, reducing reliance on manual skill, and improving the process turnover rate of the six-sided edge sealing of the mattress.

[0040] In one embodiment, in step S1, the composite assembly table 3 automatically adjusts the size of the conveyor table according to the set product size and forms an assembly frame. The composite assembly table 3 is suitable for assembling mattresses with a length of 1.6-2.2 meters, a width of 0.7-2.2 meters, and a thickness of 0.1-0.42 meters.

[0041] In one embodiment, during step S4, if the collision stop mechanism is touched during the descent of the top conveyor end and the placement of the mattress core by personnel, a touch stop command is triggered on the top conveyor belt 8 and the conveyor pneumatic lifting mechanism 9; after the spring reset mechanism 12 is reset, the touch stop command is released; after the touch stop command is released, the start switch is triggered again to trigger the next descent of the mattress.

[0042] In this embodiment, if a collision occurs during the lowering of the bed core, the current lowering and conveying process is immediately interrupted. Once safety is confirmed, the start signal is retried. Simultaneously, during the dimensional initialization phase, the input numerical parameters are range-checked, and the rigid positioning capability of the transmission components is used to maintain forming tolerances. At process nodes involving downward displacement and material transfer, the feedback level of the collision sensing element is set to the highest interrupt priority. If the level changes abruptly, the current execution process is forcibly frozen. After safety confirmation, a manual command must be reapplied to close the execution loop. This solidifies a safe and fault-tolerant process flow, preventing equipment damage or personnel injury caused by forced operation under abnormal conditions, and improving the engineering practicality and reliability of the process method. Specifically, after the composite assembly table 3 completes the size adjustment, it obtains the actual positions of the left and right reference rods 25 and the front reference rod 30. When the positional deviation between the actual position and the corresponding target position is within the preset allowable deviation range, the composite assembly table 3 is determined to be in the assembly allowable state. The top layer conveyor belt 8 of the double-layer inclined conveyor 2 starts conveying, the conveyor pneumatic lifting mechanism 9 descends, and the top layer conveyor belt 8 reverses, respectively, with the collision stop mechanism being in an untriggered state as the execution condition. When the collision stop mechanism changes from an untriggered state to a triggered state, the current execution action of the top layer conveyor belt 8 and the conveyor pneumatic lifting mechanism 9 is stopped. When the collision stop mechanism returns to an untriggered state and receives a start signal again, the corresponding execution action is resumed. Both sets of collaborative operation signals are valid within the preset operation coordination time. When the composite assembly table 3 is in the assembly-allowed state, the collision stop mechanism is in the untriggered state, and the mattress core is carried by the top conveyor belt 8, the top conveyor belt 8 is controlled to transport and lower the mattress core. The preset allowable deviation is determined based on the servo positioning accuracy, position feedback resolution, and mattress assembly size requirements of the composite assembly table 3. Allowable deviation parameters in the length and width directions are stored in the control system for different mattress specifications. When the equipment executes the current product specification, the corresponding parameters are called.

[0043] In this embodiment, after the composite assembly table 3 completes servo adjustment, the control system first determines whether the actual position meets the assembly allowable state before executing the subsequent bottom cotton felt conveying. Thus, the size setting is no longer simply a servo motion command, but becomes a prerequisite state for subsequent assembly processes. The top layer conveyor belt 8, the conveying pneumatic lifting mechanism 9, and the collision stop mechanism are interlocked according to priority; when the collision stop mechanism changes from a non-triggered state to a triggered state, the control system stops the current operation of the top layer conveyor belt 8 and the conveying pneumatic lifting mechanism 9; after the collision stop mechanism returns to a non-triggered state, the control system continues to detect the start signal, and re-enters the core conveying control process after the start signal is established.

[0044] Furthermore, a first operation confirmation signal and a second operation confirmation signal are acquired respectively (the first operation confirmation signal and the second operation confirmation signal correspond to two operators respectively); when the first operation confirmation signal is generated, the first moment is recorded. Record the second moment when the second operation confirmation signal is generated. Calculate the time interval difference between the first operation confirmation signal and the second operation confirmation signal: Based on the time interval difference, and a pre-set operation coordination time threshold. TAB Compare the two operators' confirmation actions and determine whether they belong to the same collaborative operation. when When both operation confirmation signals are valid, and the composite assembly table 3 is in the assembly allowed state, the safety limit state is in the untriggered state, and the bed core is in the top layer conveyor belt 8 bearing state, the control system sets the bed core conveying state to allowed.

[0045] when If any operation confirmation signal is invalid, assembly permission is not granted, or safety limit is triggered, the control system maintains the top conveyor belt 8 in a stopped state and maintains the current process state. The preconditions for core conveying are constituted by dimensional status, safety status, and dual-person collaborative status, subjecting the core conveying action to the combined constraints of product specifications, equipment positioning, and personnel operation.

[0046] In one embodiment, the method further includes: acquiring the actual positions of the left and right reference rods 25 and the front reference rod 30; comparing the actual positions with the corresponding target positions to obtain the position deviation in the length direction and the position deviation in the width direction; when the position deviation in the length direction or the position deviation in the width direction exceeds the corresponding preset allowable deviation, controlling the left and right servo opening and closing mechanism 17 or the servo fixed-length pneumatic lifting mechanism 16 to perform position compensation, and reacquiring the corresponding actual positions after the position compensation is completed; when the reacquired actual positions are all within the corresponding preset allowable deviation range, controlling the pneumatic positioning device 40 to execute the locking command; The actual position of the reference rod after the pneumatic positioning device 40 has completed locking is obtained. The actual position after locking is compared with the actual position before locking to obtain the amount of change in locking position. When the amount of change in locking position exceeds the preset allowable locking deviation, the locking state of the pneumatic positioning device 40 is released, and the position compensation and locking commands are re-executed. During the continuous production of mattresses of the same specification, the compensation amount corresponding to the position compensation of each batch during the continuous production process is recorded, and the position compensation parameter corresponding to the mattress specification is determined based on the recorded compensation amount. The position compensation parameter is then superimposed on the target position of the next batch of mattresses of the same specification.

[0047] In this embodiment, after the composite assembly table 3 completes the size adjustment, the control system first reads the position feedback value of the servo mechanism and uses the servo position feedback value as the actual position, instead of directly using the target position in the servo motion command as the final position of the reference rod.

[0048] Let the target position in the length direction be denoted as The actual location is recorded as Calculate the positional deviation in the length direction. The target position in the width direction is denoted as The actual location is recorded as The positional deviation in the width direction is calculated as follows: Next, determine respectively and Whether it is within the corresponding allowable deviation range.

[0049] When the position deviation in any direction exceeds the allowable range, the control system generates a compensating position command based on the error direction. For example, when And when the allowable deviation is exceeded, the servo-controlled fixed-length pneumatic lifting mechanism 16 is corrected towards the target length position; when Furthermore, if the allowable deviation is exceeded, the left and right servo opening and closing mechanisms 17 are controlled to correct the deviation in the direction of the target width position.

[0050] After position compensation is completed, the actual position is reread and the position deviation in the length direction EL and the position deviation in the width direction EW are recalculated. When the position deviations in both directions meet the allowable range, the pneumatic positioning device 40 is controlled to execute the mechanical locking command.

[0051] After the pneumatic positioning device 40 completes locking, the control system reads the actual position of the reference rod again and calculates the changes in length and width locking positions respectively: Length locking position change Width locking position change: ;in, and These represent the actual positions in the length and width directions before locking, respectively. and These represent the actual positions after locking.

[0052] when and When all values ​​are within the allowable locking deviation range, the assembly reference locking state is determined to be established; when the change in locking position in any direction exceeds the allowable range, the control system releases the locking state of the pneumatic positioning device 40 and re-executes position compensation and mechanical locking.

[0053] This embodiment records the actual compensation amount after each position compensation is completed for the same mattress specification. The control system continuously records the corresponding compensation data according to the production batch and performs statistical processing on the compensation amounts within the preset valid data range to obtain the position compensation parameters corresponding to that specification.

[0054] In this embodiment, for length direction compensation data and width direction compensation data The control system uses a weighted calculation method based on continuous samples to obtain the position compensation parameters for the current specifications: Length position compensation parameters: Width position compensation parameters: ;in, For the pre-set data update coefficients, and These are the length and width position compensation parameters saved from the previous production cycle.

[0055] The corresponding position compensation parameters are saved for different mattress specifications, and the historical compensation data of the same specification is not directly used for the target position correction of another specification.

[0056] This invention performs position compensation by using the target position and the actual position, and then performs continuous control by mechanical locking and post-locking verification after compensation. This ensures that the assembly benchmark establishment includes not only servo positioning judgment, but also confirmation of the actual position after mechanical locking. Furthermore, by forming standardized position compensation parameters through continuous production data of the same mattress specification, repeatable positioning errors can be incorporated into the position control process of subsequent products, thereby improving the consistency of the assembly benchmark in different production batches.

[0057] In one embodiment, the method further includes: after the four-sided sponge strips are placed, the placement completion status of the four-sided sponge strips is confirmed by corresponding first operation confirmation signals and second operation confirmation signals; the generation time of the first operation confirmation signal and the generation time of the second operation confirmation signal are obtained, and the time difference between the two generation times is calculated; when both the first operation confirmation signal and the second operation confirmation signal are valid, the time difference is less than or equal to a preset operation coordination time, and the composite assembly table 3 is in an assembly-allowed state, the placement completion status of the four-sided sponge strips is determined as the bed core entering an allowed state; when the first operation confirmation signal or the second operation confirmation signal is invalid, or the time difference is greater than the preset operation coordination time, or the composite assembly table 3 is not in an assembly-allowed state, the top layer conveyor belt 8 is controlled to remain stopped.

[0058] In this embodiment, the actual placement of the surrounding sponge strips is completed by an operator or a robotic arm, and the assembly reference frame is used to provide corresponding positioning references in the length and width directions. The first and second operation confirmation signals are not used to directly drive the bed core conveying, but are used to establish the completion state of the surrounding sponge strip placement. When the time difference between the two sets of operation confirmation signals exceeds the preset operation coordination time, the control system cancels the current placement completion state.

[0059] The validity of the two operation confirmation signals is jointly determined by the assembly permission status of the composite assembly table 3. Even if both confirmation signals are valid, the control system will maintain the top conveyor belt 8 in a stopped state as long as the composite assembly table 3 is not in an assembly permission status. The preset operation coordination time is determined based on the time distribution of the two operators completing the sponge strip placement and confirmation actions during actual operation, and is calibrated through actual production tests.

[0060] By transforming the manual placement of sponge strips—an action originally dependent on operator judgment—into a completed state that can be recognized by the control system, a clear process release relationship is established between sponge strip assembly and bed core conveying. Through the joint control of operation confirmation status, assembly reference status, and bed core load-bearing status, while maintaining the existing two-person collaborative operation mode, the bed core conveying action is constrained by the completed sponge strip assembly status of the surrounding area.

[0061] In one embodiment, the method further includes: during the operation of the top conveyor belt 8, acquiring the conveying displacement and driving load of the top conveyor belt 8, and calculating the displacement change of the current conveying displacement relative to the reverse return starting position and the load change of the current driving load relative to the reference load, respectively. The load transfer state of the bed core is determined based on the displacement change and load change. When the displacement change reaches a preset load transfer displacement range and the load change reaches a preset load transfer load range, the bed core is determined to be in a load transfer state, and the top conveyor belt 8 is controlled to run at a first retraction speed. When the bed core is in the load transfer state and the displacement change reaches a preset low-speed retraction position range, the top conveyor belt 8 is controlled to switch from the first retraction speed to a second retraction speed lower than the first retraction speed. When the conveying displacement of the top conveyor belt 8 reaches a preset release position and the driving load reaches a preset release load range, the bed core is determined to be in a release-allowed state, and the top conveyor belt 8 is controlled to stop reversing. When the conveying displacement changes but the driving load does not enter the corresponding load transfer load range, the bed core is determined to be in an abnormal load state, the reversing operation of the top conveyor belt 8 is stopped, and the bed core reversing is re-executed after receiving the bed core retraction start signal again.

[0062] In this embodiment, the control system establishes a core-bearing reference state before the top conveyor belt 8 reverses. The core-bearing reference state includes a drive load reference value corresponding to when the top conveyor belt 8 is in the core-bearing state. and the reference value of the conveying displacement at the start of the reverse return. .

[0063] The drive load can be obtained based on the current feedback value or torque feedback value output by the drive motor controller of the top conveyor belt 8; the conveying displacement is obtained based on the feedback value of the servo encoder of the top conveyor belt 8. The control system acquires the drive load at the current sampling moment within a continuous sampling period. and the transport displacement at the current sampling time And calculate the load change of the current drive load of the top conveyor belt relative to the reference load carried by the bed core. It is used to reflect the change in the load state of the bed core on the top conveyor belt relative to a reference state: and to calculate the change in the current conveying displacement of the top conveyor belt relative to the starting position of the reverse return. ; Furthermore, to reduce the impact of single-sample fluctuations on state judgment, the control system acquires the driving load at the current sampling moment within a continuous sampling period. And obtain the continuous samples within the current sampling window. The driving load corresponding to each sampling time Calculate the average driving load And based on the average driving load and the bearing reference load The difference between them determines the load change: ;in, For continuous sampling within the current sampling window The average value of each drive load sample.

[0064] During the equipment commissioning phase, the driving load data of the top conveyor belt 8 during no-load operation, stable bearing of the bed core, and the process of the bed core being transferred from the top conveyor belt 8 to the composite assembly table 3 were recorded respectively, and the bearing transfer judgment interval was established in combination with the corresponding conveying displacement data.

[0065] For different mattress sizes, corresponding reference load and load transfer range are established. After switching mattress sizes, the control system calls the reference parameters corresponding to the current size, and does not directly mix the load parameters of different mattress sizes.

[0066] In the initial stage of reverse retraction of the top conveyor belt 8, when the change in conveying displacement reaches the preset load transfer displacement range and the change in driving load enters the preset load transfer load range, the control system determines the bed core state as the load transfer state.

[0067] After the bed core is in the load-bearing transfer state, the top conveyor belt 8 returns at the first retraction speed. Operation. When the change in conveyor displacement reaches the preset low-speed retraction position range, the control system switches the retraction speed to the second retraction speed. and satisfy ;in, Indicates the first retraction speed. This indicates the second return speed.

[0068] As the top conveyor belt 8 continues to run in reverse, the control system continuously acquires the conveying displacement and drive load. When the conveying displacement reaches the preset release position... And drive the load into the preset load release range. At that time, the bed core is determined to be in the state where release is permitted.

[0069] In this embodiment, the allowable release state is determined jointly by displacement conditions and load conditions: ,and ;in Indicates the allowable deviation of the release position. and These represent the lower and upper limits of the load release range, respectively. The actual conveying displacement of the top conveyor belt at the current sampling moment is obtained from the displacement feedback signal of the top conveyor belt. The actual drive load value of the top conveyor belt at the current sampling moment is obtained from the current feedback value or torque feedback value output by the drive motor controller.

[0070] When both of the above conditions are met simultaneously, the control system stops the top conveyor belt 8 from continuing to run in reverse and sets the core release state to complete. If the top conveyor belt 8 has already undergone displacement change but the driving load has not entered the load transfer range, the control system determines the current core state as an abnormal load state. For example: ,and If the current change in conveying displacement does not satisfy the predetermined load transfer relationship, then it is determined that the change in load transfer does not meet the predetermined load transfer relationship. This refers to the change in conveyor displacement of the top conveyor belt relative to its initial reverse return position. This represents the change in load between the current drive load and the reference load borne by the bed core. This is a preset displacement threshold used to determine whether the bed core has entered the abnormal load state detection area; When an abnormal load condition occurs, the control system stops the reverse operation of the top conveyor belt 8 and maintains the current state of the core and the top conveyor end. After the abnormality is handled, the core retraction start signal is obtained again, the current core load reference load is re-established, and the load transfer control is re-entered at the first retraction speed.

[0071] In this embodiment, the determination of abnormal load conditions is not based on a single current value, but rather considers the correspondence between changes in conveyor displacement and changes in drive load simultaneously, thereby distinguishing between two types of states: movement of the conveyor mechanism and changes in the load condition of the mattress core. Furthermore, the first and second retraction speeds are calibrated during the equipment debugging phase based on the mattress core specifications, the operational stability of the top conveyor belt 8, and the positional changes during the mattress core release process; the load transfer range, low-speed retraction position range, and release load range are determined based on actual test data for different mattress specifications.

[0072] In this embodiment, by jointly determining the state between the conveying displacement and the driving load, the reverse retraction of the top conveyor belt 8 is no longer executed according to a fixed time or a single position, but rather the speed switching and release control are based on the bed core's load-bearing state. By coupling the displacement change with the driving load change, a first retraction speed is used when the bed core is in the load transfer state, and a second retraction speed is switched after entering the low-speed retraction position. The release state is determined by both displacement and load, making the transfer process of the bed core from the top conveyor belt 8 to the composite assembly table 3 a dynamic control process with state feedback. When the conveying displacement change and the driving load change do not meet the predetermined correspondence, the retraction stops, preventing the control system from continuing to execute the retraction action according to the predetermined conveying trajectory, thereby improving the state controllability of the bed core receiving process.

[0073] In one embodiment, the method further includes: obtaining the completion time of the adhesive spraying of the top cotton felt; obtaining the current time in real time, and determining the current waiting time based on the time interval between the current time and the completion time of the adhesive spraying; determining the effective bonding time start value and effective bonding time end value based on the bonding test data corresponding to the adhesive spraying process, and establishing an effective bonding time window based on the effective bonding time start value and effective bonding time end value. When the current waiting time is less than the effective bonding time start value, the inclined conveyor is controlled to keep the top cotton felt in the waiting position; when the current waiting time is greater than or equal to the effective bonding time start value and less than or equal to the effective bonding time end value, and the bed core is in the allowable release state, the inclined conveyor is controlled to transport the top cotton felt to the corresponding bonding position; when the current waiting time is greater than the effective bonding time end value, the inclined conveyor is prohibited from transporting the top cotton felt to the normal bonding position, and an abnormal processing signal is output; wherein, the effective bonding time start value and the effective bonding time end value are determined according to the glue spraying parameters of the corresponding glue spraying process and the actual bonding test results.

[0074] In this embodiment, the top cotton felt enters the waiting position of the inclined conveyor 1 after the adhesive spraying process is completed at the front end. The control system records the time when the adhesive spraying is completed. And continuously record the current time. According to the time when the glue spraying is completed and current time Calculate the current waiting time after the top cotton felt is sprayed with adhesive: This study establishes bonding time tests for the currently used adhesive spraying equipment, adhesives, top cotton felt materials, and mattress specifications. Multiple waiting time points are set after adhesive spraying, and the top cotton felt and mattress core are bonded under the same adhesive spraying process conditions. The consistency of the bonded adhesion is then tested. The bonding test records at least the adhesive spraying completion time, the start of bonding time, and the bonding completion state to obtain bonding results corresponding to different waiting times. Based on production quality requirements, a time interval that continuously meets quality requirements is selected, and the start time of this interval is determined as the effective bonding time starting value. The end time of this interval is determined as the effective fitting time end value. The starting value of the effective bonding time is determined based on the bonding test. and the end value of effective bonding time And wait time after spraying glue. In to The time interval between these points is determined as the effective time window, which satisfies: At that time, it is determined that the top cotton felt is in an effective bonding state.

[0075] Establish corresponding effective bonding time windows for different adhesive spraying process parameters. When the adhesive spraying process parameters change, re-call the time window corresponding to the corresponding process parameters to avoid using the same time window for different adhesive spraying conditions.

[0076] when When the control system keeps the inclined conveyor 1 stopped or keeps the top cotton felt in a waiting position, the waiting time of the top cotton felt continues to increase; when And when the bed core is in the allowable release state, the control system opens the top cotton felt conveying state, so that the inclined conveyor 1 conveys the top cotton felt to the corresponding bonding position. When When this happens, the control system cancels the current normal bonding state of the top surface cotton felt and outputs an abnormality handling signal to prevent the top surface cotton felt from continuing to enter the subsequent assembly process according to the normal bonding process.

[0077] When the mattress core has not yet reached the permitted release state but the top cotton felt has already been glued, the control system simultaneously acquires the current waiting time. And the estimated remaining release time determined based on the current load transfer status of the bed core. And calculate the expected waiting time: The control system determines the expected waiting time. Starting value of effective bonding time The relationship between the effective bonding time and the end value determines the conveying status of the top cotton felt after the bed core is released.

[0078] when At that time, after the bed core is fully released, the top cotton felt remains in a waiting state; when At that time, the bed core release state is directly connected with the top cotton felt conveying state; when When the bed core is released, the system enters a time window over-limit warning state and outputs a corresponding abnormal cycle signal.

[0079] Remaining release time The determination is based on the current reverse retraction displacement of the bed core, the current retraction speed, and the load transfer status; when the bed core moves from the first retraction speed... Switch to the second rewind speed Then, based on the current remaining conveying displacement and the second retraction speed... Updated estimated remaining release time.

[0080] In this embodiment, by simultaneously incorporating the glue spraying completion time, the top cotton felt waiting time, the bed core load transfer state, and the bed core release state into the control, the top cotton felt conveying process is subject to the joint constraints of material processing time and mechanical assembly state. By limiting the moment the top cotton felt enters the bonding position through an effective bonding time window, the waiting time after glue spraying of the top cotton felt has a clear process judgment condition; by involving the bed core release state in the conveying permission judgment, a continuous control relationship is formed between the material processing state of the top cotton felt and the mechanical assembly state of the bed core.

[0081] In this invention, firstly, the target assembly dimensions of the composite assembly platform 3 are determined according to the specifications of the mattress to be assembled. The left and right reference rods 25 and the front reference rod 30 are adjusted using the left and right servo opening and closing mechanism 17 and the servo fixed-length pneumatic lifting mechanism 16, and the position of the rear reference rod 23 is adjusted using the rear reference pneumatic lifting mechanism 15. After the composite assembly platform 3 completes its initial adjustment, the control system acquires the actual positions of the left and right reference rods 25 and the front reference rod 30, and calculates the length and width position deviations between the actual and target positions. When any position deviation exceeds the allowable deviation range, the control system performs corresponding position compensation and reacquires the actual position. When the actual position meets the allowable deviation range, the pneumatic positioning device 40 is controlled to lock the assembly reference, and the locked actual position is verified.

[0082] After the baseline state is established, the bottom cotton felt is conveyed to the composite assembly table 3 by the inclined conveyor 1, and its position is determined under the limit of the assembly baseline frame.

[0083] Subsequently, the operators place the surrounding sponge strips according to the assembly reference frame. Two operators generate a first operation confirmation signal and a second operation confirmation signal, respectively, and the control system calculates the time difference between the two confirmation signals. When both confirmation signals are valid and the time difference is within the preset operation coordination time, and the composite assembly table 3 maintains the assembly permission state, the placement of the surrounding sponge strips is determined as the bed core entering the permission state.

[0084] Once the bed core enters the permitted state, the top conveyor belt 8 is controlled to transport the bed core above the composite assembly table 3, and the pneumatic lifting mechanism 9 is controlled to descend. After the bed core reaches the receiving position, the top conveyor belt 8 reverses its direction. The control system continuously acquires the conveying displacement and driving load of the top conveyor belt 8, and determines the bed core load transfer state based on the displacement change and load change.

[0085] When the mattress core enters the load transfer state, the top-layer conveyor belt 8 operates at a first retraction speed V1; when the conveying displacement reaches the low-speed retraction position range, the retraction speed is switched to a second retraction speed V2, where V2 < V1; when the conveying displacement reaches the release position and the driving load enters the release load range, it is determined that the mattress core is in the allowable release state and the top-layer conveyor belt 8 stops continuing to run in the reverse direction. During the retraction process of the mattress core, when the top surface felt has completed the glue spraying treatment, the control system records the glue spraying completion moment and continuously calculates the waiting time of the top surface felt; at the same time, the estimated remaining release time is determined according to the current load transfer state of the mattress core, and the estimated waiting time of the top surface felt after the mattress core is released is calculated.

[0086] When the estimated waiting time is within the effective lamination time window and the mattress core has completed the confirmation of the allowable release state, the control system opens the top surface felt conveying authority of the inclined conveyor 1, so that the top surface felt enters the corresponding lamination position; when the estimated waiting time has not entered the effective lamination time window, the top surface felt remains at the waiting position; when the estimated waiting time exceeds the end value of the effective lamination time window, the control system enters an abnormal processing state. After the lamination of the top surface felt is completed, the front reference rod 30 and the rear reference rod 23 are controlled to descend to release the limit of the mattress, and the mattress is conveyed to the subsequent pressing process by the belt conveying mechanism 19.

[0087] In the present invention, the assembly reference position compensation determines the geometric reference on which the subsequent placement of the sponge strips and the receiving of the mattress core are based; the completion state of the four peripheral sponge strips determines the access authority of the mattress core; the load transfer state of the mattress core determines the retraction speed and release timing of the top-layer conveyor belt 8; the release state of the mattress core also participates in the determination of the conveying authority of the top surface felt; the waiting time of the top surface felt further restricts the conveying timing of the inclined conveyor 1. Through the continuous connection among geometric positioning control, manual operation state control, mechanical load state control and material process time control, a process state closed loop from dimension establishment to final lamination is formed in the six-sided mattress laminating process, which reduces invalid actions and abnormal conveying conditions caused by state mismatch between the front and rear processes.

[0088] Obviously, those skilled in the art can make various modifications and variations to the present invention without departing from the spirit and scope of the present invention. Thus, provided that these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalent technologies, the present invention is also intended to cover these modifications and variations.

Claims

1. A composite assembly line for attaching top and bottom cotton felt and four-sided sealing foam strips to a mattress, characterized in that, include: Inclined conveyor (1) is used to receive the bottom cotton felt, bed core and top cotton felt sent out by the front spraying process, and to perform horizontal conveying or pneumatic inclined conveying according to the process rhythm. The double-layer inclined conveyor (2) is located at the output end of the inclined conveyor (1) and is used to receive the bed core and top cotton felt conveyed by the inclined conveyor (1), and convey the bed core and top cotton felt to the designated assembly position through its top layer conveying mechanism (8) to cooperate with the bed core for lowering. The composite assembly table (3) is located below the conveying end of the double-layer inclined conveyor (2) and is used to automatically adjust and form an assembly reference frame according to the set mattress size, so as to receive the bottom cotton felt, position the surrounding sponge strips, and receive the bed core and top cotton felt put down from the double-layer inclined conveyor (2) for six-sided composite bonding.

2. The composite assembly line for attaching upper and lower cotton felt and four-sided sealing foam strips to a mattress as described in claim 1, characterized in that, The composite assembly platform (3) includes a bakelite tabletop, left and right reference rods (25), a rear reference pneumatic lifting mechanism (15), and a servo fixed-length pneumatic lifting mechanism (16). The left and right reference rods (25) are linked with the bakelite tabletop and automatically move into place according to the set mattress size. The rear reference pneumatic lifting mechanism (15) and the servo fixed-length pneumatic lifting mechanism (16) are used to control the lifting of the reference rods to form a foam assembly frame.

3. The composite assembly line for attaching upper and lower cotton felt and four-sided sealing foam strips to a mattress as described in claim 2, characterized in that, The composite assembly table (3) includes a servo linkage table (18) and a belt conveyor mechanism (19) set on the table. The left and right reference rods (25) are driven by the left and right servo opening and closing mechanism (17), which includes a linear guide rail (26), a linkage power rod (27) and a synchronous belt drive structure (28), used to drive the left and right reference rods (25) to move in opposite directions or backwards to adjust the width reference of the mattress. The rear reference pneumatic lifting mechanism (15) includes a vertically arranged pneumatic lifting mechanism (21), the power output end of which is connected to the rear reference rod (23) for controlling the raising and lowering of the rear reference rod (23); The servo fixed-length pneumatic lifting mechanism (16) includes a front reference rod (30) and drives a linear guide rack servo transmission mechanism (33) via a motor (35) to move and position in the length direction to adapt to different mattress lengths; the front reference rod (30), the rear reference rod (23) and the left and right reference rods (25) rise together to form the sponge assembly frame.

4. The composite assembly line for attaching upper and lower cotton felt and four-sided sealing foam strips to a mattress as described in claim 1, characterized in that, The side of the servo linkage table (18) is also provided with a pneumatic positioning device (40) and a linkage sensing mechanism to perform positioning and locking after the table size is adjusted. The linkage sensing mechanism includes a vertical plate (36), a sensing reference plate (37) disposed on the vertical plate (36), a sensing connection plate (44), and a linkage sensing sensor (45). The pneumatic positioning device (40) is fixed by angle iron (41) and provides a support structure in conjunction with the longitudinal connecting rod (43); the induction connecting plate (44) is provided with an assembly hole (38), and a linkage induction sensor (45) is installed on the assembly hole (38). The power output end of the pneumatic positioning device (40) is set in accordance with the assembly hole (38) and is used for pneumatic pin positioning after the table is adjusted to the position. The edge of the servo linkage table (18) is also provided with a side stand (42), and its bottom is provided with a linkage guide rail (46), a linkage rod (47) and a linkage track (48) to cooperate with the linkage sensing sensor (45) to realize position signal feedback and smooth guidance during the sliding process.

5. A composite assembly line for attaching upper and lower cotton felt and four-sided sealing foam strips to a mattress as described in claim 1, characterized in that, The top layer conveying end of the double-layer inclined conveyor (2) is provided with a conveying pneumatic lifting mechanism (9); the top layer conveying end can pneumatically descend while starting the top layer conveying to reduce the height difference for receiving and placing the bed core.

6. A composite assembly line for attaching upper and lower cotton felt and four-sided sealing foam strips to a mattress as described in claim 5, characterized in that, The top conveying end of the double-layer inclined conveyor (2) is also provided with a collision stop mechanism and a spring reset mechanism (12). When an operator or object touches the collision stop mechanism, the top conveyor belt (8) and the conveyor pneumatic lifting mechanism (9) are triggered to stop. When the touch stops, it is reset by the spring reset mechanism (12) and resumes operation after the switch is restarted.

7. A composite assembly line for attaching upper and lower cotton felt and four-sided sealing foam strips to a mattress as described in claim 1, characterized in that, The double-layer inclined conveyor (2) is installed on the frame (6) and includes a horizontal conveyor belt (7) at the lower layer and a top layer conveyor belt (8) at the upper layer; the bottom of the conveying end of the top layer conveyor belt (8) is connected to the conveying pneumatic lifting mechanism (9), which is used to adjust the height of the top layer conveyor belt (8); The collision stop mechanism is located on the outer side of the end of the top conveyor belt (8), and the collision stop mechanism includes a safety limit switch (11) located on one side of the spring reset mechanism (12). The spring reset mechanism includes a fixed plate (12), a guide post (13), and a reset plate (14). The fixed plate (12) is located on the outer side of the end of the top conveyor belt (8). The guide post (13) is located on the side of the fixed plate (12) away from the safety limit switch (11). A spring is provided on the guide post (13). The spring is connected to the reset plate (14). The reset plate (14) passes through the guide post (13) and reciprocates on the guide post (13) according to the working state of the spring. In the normal state, the spring reset mechanism (12) supports the reset plate (14) to protrude outward. When the reset plate (14) is impacted and squeezed inward, the spring reset mechanism (12) is compressed and the safety limit switch (11) is triggered, thereby controlling the top conveyor belt (8) to stop running and the conveyor pneumatic lifting mechanism (9) to stop descending.

8. A composite assembly line for attaching upper and lower cotton felt and four-sided sealing foam strips to a mattress as described in claim 1, characterized in that, It also includes a dual-person collaborative control system, which is connected to a common start switch and a foot switch; the top layer conveying start of the double-layer inclined conveyor (2) needs to be triggered by two sets of switches, and the top layer conveying mechanism is retracted or conveyed through the foot switch.

9. A mattress assembly method using a composite assembly line for attaching upper and lower cotton felt and four-sided sealing foam strips as described in any one of claims 1-8, characterized in that, Includes the following steps: S1. Set the required mattress size, and move the left and right reference rods (25) of the composite assembly table (3) to the specified size position. The rear reference pneumatic lifting mechanism (15) and the servo fixed length pneumatic lifting mechanism (16) raise the front reference rod (30) and the rear reference rod (23). S2. After the bottom cotton felt is sprayed with glue, it is horizontally conveyed from the inclined conveyor (1) to the table surface of the composite assembly table (3). S3, Reset the reference rod, place the surrounding sponge strips along the left and right reference rods (25) of the composite assembly table (3), and the bed core is conveyed to the upper layer of the double-layer inclined conveyor (2) by the inclined conveyor (1); S4. Trigger the start switch, the top layer of the double-layer inclined conveyor (2) is conveyed and the top layer conveyor end is pneumatically lowered. After reaching the designated position, trigger the foot switch, the top layer conveyor belt (8) retracts, and the bed core is placed in the center of the composite assembly table (3). S5. The top cotton felt is sprayed with glue and reaches the inclined position of the inclined conveyor (1). After the top conveyor belt (8) returns, the top cotton felt is conveyed to the rear reference position and the top cotton felt is bonded. S6. After attaching the top cotton felt, turn on the switch to raise the front reference rod (30) and the rear reference rod (23) and transport the attached mattress to the next pressing process.

10. The mattress assembly method according to claim 9, characterized in that, In step S1, the composite assembly table (3) automatically adjusts the size of the conveyor table according to the set product size and forms an assembly frame. The composite assembly table (3) is suitable for assembling mattresses with a length of 1.6-2.2 meters, a width of 0.7-2.2 meters, and a thickness of 0.1-0.42 meters. In step S4, if the collision stop mechanism is touched during the descent of the top conveyor end and the personnel receiving and placing the bed core, the collision stop command of the top conveyor belt (8) and the conveyor pneumatic lifting mechanism (9) will be triggered. After the spring reset mechanism (12) is reset, the touch stop command is released; after the touch stop command is released, the start switch is triggered again to trigger the next lowering action of the mattress.

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