Modular sponge cushion full-automatic flexible cutting and bonding production system

Abstract

The application discloses a kind of modular sponge cushion full-automatic flexible cutting and bonding production system, including cross rail frame, ground rail assembly, bearing pedestal, ball and omnidirectional supporting wheel;Laser cutting head and adhesive spraying head are respectively installed in the both sides of cross rail frame, and the circumferential deflection of cross rail frame is driven by ground rail assembly, realizes the multi-angle coverage of processing mechanism;First drive motor and second drive motor are arranged in bearing pedestal and drive omnidirectional supporting wheel movement, and omnidirectional supporting wheel includes hub, shaft and rotating roller, and the helical rack on the surface of shaft and the worm gear groove on the surface of rotating roller are engaged transmission, so that rotating roller synchronous rolling is realized, and the omnidirectional conveying, rotation and posture adjustment of sponge workpiece are realized by cooperating with the deflection of hub.The laser cutting, adhesive spraying and omnidirectional conveying are integrated in the same equipment platform in the application, realize the continuous automatic processing of sponge cushion cutting, glue spraying and positioning, with the advantages of high processing efficiency, high positioning accuracy, high flexibility, suitable for multi-specification product production and strong modular expansion capability.

Description

Technical Field

[0001] This invention relates to the field of automated processing technology for sponge products, specifically a modular, fully automated, flexible cutting and bonding production system for sponge cushions. Background Technology

[0002] Currently, sponge cushion production often employs an independent production model where cutting, gluing, and conveying equipment operate independently. After completing one process, the sponge needs to be transferred to the next station for further processing. This not only increases material handling time but also easily leads to cumulative errors due to multiple positioning steps, affecting subsequent bonding accuracy. Furthermore, existing conveying mechanisms mostly use single-direction conveying methods such as belts, rollers, or chains. When the sponge needs to change its posture, rotation direction, or processing angle, it typically relies on mechanical clamping, manual flipping, or re-clamping, which not only affects the processing cycle but also fails to meet the continuous processing requirements of complex-shaped sponge cushions. In addition, traditional gantry mechanisms generally only allow linear movement in a fixed direction, limiting the processing range due to equipment layout. For irregularly shaped sponges or products of different specifications, additional motion mechanisms are often required to complete all processing actions, making the overall equipment structure complex, occupying a large area, lacking flexibility, and hindering future modular expansion and production line upgrades.

[0003] In view of this, this paper studies and improves the existing problems, and provides a modular fully automatic flexible cutting and bonding production system for sponge cushions to solve the current problems. The aim is to solve the problems and improve the practical value through this technology. Summary of the Invention

[0004] The present invention aims to solve the problems in the existing sponge cushion production process, such as the independent cutting, glue spraying and conveying equipment, the need for frequent transfer and repeated positioning of workpieces, the difficulty in achieving omnidirectional movement and flexible processing of sponge workpieces, resulting in low production efficiency, insufficient processing accuracy and poor equipment flexibility.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: A modular, fully automated flexible cutting and bonding production system for sponge cushions includes a horizontal rail frame, a ground rail assembly, a support base, and several ball bearings and omnidirectional rollers arranged on the surface of the support base. Lifting rails are slidably installed on both sides of the horizontal rail frame. The surfaces of the two lifting rails are respectively equipped with a laser cutting head and an adhesive spraying head. The ground rail assembly includes a stator ring rail and a rotor ring rotatably fitted inside the stator ring rail. The bottom end of the horizontal rail frame is fixedly connected to the top surface of the rotor ring, used to drive the horizontal rail frame to perform circumferential deflection motion. A first drive motor and a second drive motor are fixedly installed inside the support base. The omnidirectional rollers include a hub, a shaft, and several rollers rotatably installed on the surface of the hub. One side of the hub is provided with a transmission wheel that is driven by the output end of the first drive motor. The end of the shaft is driven by the output end of the second drive motor. One end of the shaft is provided with a worm gear rack located inside the hub. The surface of the rollers is provided with worm tooth grooves that mesh with the worm gear rack.

[0006] Using the above structure, the circumferential deflection of the processing mechanism is achieved through the horizontal rail frame and the ground rail assembly, and the omnidirectional support rollers on the support base drive the sponge workpiece for omnidirectional transport. This allows the sponge cushion to complete posture adjustment without repeated clamping. At the same time, the cutting and glue spraying processes are integrated into the same equipment platform, improving processing efficiency and flexible production capabilities.

[0007] In a preferred embodiment, the omnidirectional rollers are evenly distributed on the surface of the support base, and the balls are evenly distributed in the non-distribution areas of the omnidirectional rollers. The top surface of the balls and the top surface of the omnidirectional rollers are on the same horizontal plane, so that the sponge workpiece can form uniform support after being placed, thereby reducing the moving resistance and improving the stability of the workpiece conveying, and avoiding local pressure deformation.

[0008] In a preferred embodiment, the stator ring rail is further configured such that a coil stator structure is provided on the inner side of the stator ring rail, and a permanent magnet sheet is provided on the surface of the rotor ring opposite to the coil stator. The rotor ring is driven to deflect by direct drive, so that the horizontal rail frame can rotate continuously around the center of the support base, thereby improving the processing coverage and reducing the transmission backlash of the traditional rotary mechanism.

[0009] In a preferred embodiment, the transverse rail frame is configured as a gate-shaped or L-shaped frame structure, with electromagnetic slide rails or lead screw slide rails on both sides to drive the laser cutting head and adhesive spraying head to move independently, so that the two processing heads can move synchronously according to different processing trajectories, realize continuous cutting and adhesive spraying processing, and improve the overall utilization rate of the equipment.

[0010] In a preferred embodiment, the roller is further configured such that the rotating roller is spindle-shaped, the worm gear and the worm tooth groove are engaged, and when the shaft rotates, each roller rolls synchronously around its own axis, thereby driving the sponge workpiece to move in a set direction; through the overall deflection of the hub and the rolling of the roller in coordination, the workpiece can complete multi-directional movements such as longitudinal, transverse, oblique and rotational movements, thereby improving the flexibility of sponge cushion conveying.

[0011] In a preferred embodiment, the hub is rotatably mounted inside the support base, and several grooves are opened on the surface of the hub. Each roller is installed in a corresponding groove, and two sets of rollers are arranged alternately on both sides of the hub, so that the workpiece always maintains continuous contact support, thereby improving the smoothness of conveying and the uniformity of driving force.

[0012] In a preferred embodiment, the first drive motor is used to drive the hub to deflect as a whole, and the second drive motor is used to drive the shaft to rotate, so that the omnidirectional support roller has both directional adjustment and active conveying capabilities. Through the coordinated work of the two drive systems, high-precision omnidirectional positioning and continuous motion control of the workpiece can be achieved.

[0013] The beneficial effects achieved by this invention are as follows: 1. In this invention, by using a horizontal rail frame in conjunction with a lifting rail, and integrating a laser cutting head and an adhesive spraying head on the two lifting rails respectively, the cutting and bonding of sponge cushions can be completed continuously in the same equipment, reducing material transfer and process changeover time, improving production efficiency, and reducing positioning errors.

[0014] 2. In this invention, the omnidirectional support rollers on the surface of the support base work together with the first and second drive motors to drive each roller in an omnidirectional manner, enabling the sponge workpiece to be translated, rotated and adjusted in any direction without the need for manual flipping or repeated clamping, thus improving processing flexibility and positioning accuracy.

[0015] 3. In this invention, the stator ring rail and rotor ring of the ground rail assembly drive the transverse rail frame to rotate in a circular manner, and combined with the omnidirectional support rollers, the sponge workpiece is subjected to multi-degree-of-freedom motion control, so that the laser cutting head and adhesive spraying head can cover the entire processing area, realizing the automated and flexible production of sponge cushions of different specifications and contours, and improving the adaptability and modular expansion capability of the equipment. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of one embodiment of the present invention; Figure 2 This is a schematic diagram of the cross rail frame and ground rail assembly structure according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the surface structure of a bearing platform according to an embodiment of the present invention; Figure 4 This is a schematic diagram of the internal structure of the support base according to an embodiment of the present invention; Figure 5 This is a schematic diagram of an omnidirectional support roller structure according to an embodiment of the present invention; Figure 6 This is a schematic diagram of the hub surface structure according to an embodiment of the present invention; Figure 7 This is a schematic diagram of the shaft and roller structure according to an embodiment of the present invention.

[0017] Figure label: 100. Horizontal rail frame; 110. Lifting rail; 120. Laser cutting head; 130. Adhesive spraying head; 200. Ground rail assembly; 210. Stator ring rail; 220. Rotor ring; 300, bearing platform; 310, ball bearing; 320, first drive motor; 330, second drive motor; 400. Omnidirectional support roller; 410. Wheel hub; 420. Shaft; 430. Rotary roller; 411. Drive wheel; 412. Rotary groove; 421. Worm gear rack; 431. Worm gear groove. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings. It should be noted that, unless otherwise specified, the embodiments and features described herein can be combined with each other.

[0019] It should be understood that these descriptions are merely exemplary and are not intended to limit the scope of the invention.

[0020] The following describes, with reference to the accompanying drawings, some embodiments of the present invention, a fully automated flexible cutting and bonding production system for modular sponge cushions.

[0021] Combination Figures 1-7 As shown, the present invention provides a modular sponge cushion fully automatic flexible cutting and bonding production system, including a horizontal rail frame 100, a ground rail assembly 200, a support base 300, and a number of ball bearings 310 and omnidirectional support rollers 400 arranged on the surface of the support base 300.

[0022] The horizontal rail frame 100 serves as the processing execution mechanism and has an overall portal frame structure. Vertical guide structures are provided on both sides. Two lifting rails 110 are slidably installed on both sides of the horizontal rail frame 100. Each lifting rail 110 can move independently along the length of the horizontal rail frame 100. The lifting rails 110 preferably employ electromagnetic rails, linear motor rails, or lead screw rail structures. In this embodiment, a laser cutting head 120 is installed at the bottom of one lifting rail 110, and an adhesive spraying head 130 is installed at the bottom of the other lifting rail 110. Both can move, lift, and perform processing actions independently, allowing the cutting and adhesive spraying processes to be completed on the same equipment platform.

[0023] The ground rail assembly 200 is located at the bottom of the equipment and includes a stator ring rail 210 and a rotor ring 220 rotatably sleeved inside the stator ring rail 210. The stator ring rail 210 is fixedly installed on the equipment foundation platform and has an annular coil stator structure on its inner side. Permanent magnet sheets are correspondingly arranged on the surface of the rotor ring 220. The rotor ring 220 is driven to rotate in the circumferential direction by the working principle of the direct drive motor, thereby driving the horizontal rail frame 100 to deflect around the center of the support 300, realizing the large-angle rotational positioning of the entire processing mechanism.

[0024] The support base 300 is fixedly installed at the center of the equipment, and its top forms a sponge processing platform. Several balls 310 are evenly arranged on the surface of the support base 300. Balls 310 are arranged in the unarranged areas between the omnidirectional support rollers 400, and the top surface of each ball 310 is at the same height as the top surface of the omnidirectional support roller 400, so that the sponge cushion can form stable support after being placed and reduce movement resistance.

[0025] The support base 300 is equipped with a first drive motor 320 and a second drive motor 330. The first drive motor 320 is used to drive the omnidirectional support roller 400 to deflect as a whole, and the second drive motor 330 is used to drive the internal roller 430 of the omnidirectional support roller 400 to roll, thereby realizing the omnidirectional movement of the sponge cushion on the platform.

[0026] The omnidirectional support roller 400 includes a hub 410, a shaft 420, and several rollers 430.

[0027] The hub 410 is generally disc-shaped and is rotatably mounted inside the support 300. A transmission wheel 411 is provided on the outer periphery of the hub 410. The transmission wheel 411 is connected to the output end of the first drive motor 320. When the first drive motor 320 is working, it drives the entire hub 410 to rotate around its own axis, so that each roller 430 adjusts the driving direction as a whole.

[0028] A plurality of rotating grooves 412 are evenly opened on the surface of the hub 410, and each rotating groove 412 is used to install a corresponding rotating roller 430. Each rotating roller 430 is evenly arranged along the circumference of the hub 410.

[0029] In this embodiment, several rotating rollers 430 are divided into two groups, left and right. The two groups of rotating rollers 430 are respectively arranged on both sides of the hub 410 and are staggered, so that a continuous contact area is formed between adjacent rotating rollers 430, thereby improving the uniformity of force on the bottom of the sponge cushion and avoiding local pressure deformation during the conveying process.

[0030] The shaft 420 is located at the center of the hub 410. One end of the shaft passes through the hub 410 and is fixedly connected to the output end of the second drive motor 330. The other end is provided with a worm gear rack 421.

[0031] The spiral rack 421 is arranged in a spiral continuous manner along the outer periphery of the shaft 420. Each roller 430 has a corresponding worm tooth groove 431 on its inner side. When the second drive motor 330 drives the shaft 420 to rotate, the spiral rack 421 continuously meshes with each worm tooth groove 431, so that all rollers 430 roll synchronously around their own axis, thereby driving the sponge cushion to move in the corresponding direction.

[0032] The rotating roller 430 has an overall spindle-shaped structure with a larger diameter in the middle and gradually narrowing at both ends, which creates a better guiding capability between adjacent rotating rollers 430. Even if the sponge deviates, it can automatically correct its direction and improve the stability of conveying.

[0033] In this embodiment, each processing mechanism is connected to the control system. The control system controls the horizontal rail frame 100, the lifting rail 110, the laser cutting head 120, the adhesive spraying head 130, the ground rail assembly 200, and each omnidirectional support roller 400 to move in coordination according to the processing drawings.

[0034] The working principle and usage process of this invention are as follows: First, the sponge cushion to be processed is placed on top of the support base 300, with the bottom of the sponge simultaneously contacting and supporting several ball bearings 310 and several omnidirectional support rollers 400.

[0035] Subsequently, the control system controls the second drive motor 330 to work according to the processing program. The second drive motor 330 drives the shaft 420 to rotate, so that the worm gear rack 421 continuously drives each roller 430 to roll. Each roller 430 synchronously pushes the sponge cushion to be conveyed in a straight line along the specified direction.

[0036] When the sponge needs to change its processing direction, the control system controls the first drive motor 320 to work. The first drive motor 320 drives the transmission wheel 411 to rotate, causing the entire hub 410 to deflect synchronously. Each roller 430 changes its driving direction as a whole. Without the need for manual handling and re-clamping, the sponge can be driven to complete multi-degree-of-freedom movements such as lateral movement, longitudinal movement, oblique movement and rotation in place, realizing omnidirectional sponge conveying and positioning.

[0037] At the same time, the control system controls the ground rail assembly 200 to work according to the processing trajectory, and the stator ring rail 210 drives the rotor ring 220 to rotate, so that the horizontal rail frame 100 rotates in a circle around the center of the bearing 300, thereby expanding the processing coverage area.

[0038] During the movement of the horizontal rail frame 100, the two lifting rails 110 on both sides move independently. The laser cutting head 120 first performs contour cutting, grooving, irregular shape processing and hole punching on the sponge according to the set trajectory. After the cutting is completed, the other lifting rail 110 drives the adhesive spraying head 130 to spray adhesive along the same or different trajectories, so that the cutting and adhesive spraying can be completed continuously without changing equipment or changing work stations.

[0039] During the processing, the support base 300 can continuously drive the sponge to adjust its posture, the horizontal rail frame 100 continuously adjusts the processing angle, and the two processing heads complete different processing tasks respectively, thereby realizing continuous cutting and automatic glue spraying of the sponge cushion at any position and in any direction.

[0040] After processing, the omnidirectional roller 400 continues to drive the sponge to the unloading position, where an operator or robotic arm retrieves the material, thus completing the entire automatic flexible cutting and bonding process for the sponge cushion. In this specification, the terms "one embodiment," "some embodiments," "specific embodiment," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of the invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0041] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A modular, fully automated, flexible cutting and bonding production system for sponge cushions, characterized in that: The system includes a horizontal rail frame (100), a ground rail assembly (200), a support base (300), and several ball bearings (310) and omnidirectional rollers (400) arranged on the surface of the support base (300). The horizontal rail frame (100) is slidably mounted with lifting rails (110) on both sides. The two lifting rails (110) are respectively provided with a laser cutting head (120) and an adhesive spraying head (130). The ground rail assembly (200) includes a stator ring rail (210) and a rotor ring (220) rotatably sleeved on the inner side of the stator ring rail (210). The bottom end of the horizontal rail frame (100) is fixedly connected to the top surface of the rotor ring (220) to drive the horizontal rail frame (100) to deflect. The first drive motor (320) and the second drive motor (330) are fixedly installed on the inner side of the support base (300). The omnidirectional support roller (400) includes a hub (410), a shaft (420) and several rollers (430) rotatably mounted on the surface of the hub (410). A transmission wheel (411) is provided on one side of the hub (410) and is connected to the output end of the first drive motor (320). The end of the shaft (420) is connected to the output end of the second drive motor (330). One end of the shaft (420) is provided with a worm gear rack (421) located inside the hub (410). The surface of the roller (430) is provided with a worm tooth groove (431) that meshes with the surface of the worm gear rack (421).

2. The modular sponge cushion fully automated flexible cutting and bonding production system according to claim 1, characterized in that, Several omnidirectional rollers (400) are evenly distributed on the surface of the support base (300), and each of the balls (310) is evenly distributed in the non-distribution area of ​​the omnidirectional rollers (400). The top surface of the omnidirectional rollers (400) and the top surface of the balls (310) are located on the same horizontal plane for conveying the sponge block.

3. The modular sponge cushion fully automated flexible cutting and bonding production system according to claim 1, characterized in that, The inner side of the stator ring rail (210) is provided with a coil stator structure, and the surface of the rotor ring (220) is provided with permanent magnet sheets that are arranged opposite to the coil stator structure.

4. The modular sponge cushion fully automated flexible cutting and bonding production system according to claim 1, characterized in that, The horizontal rail frame (100) has an L-shaped or gate-shaped frame structure, and electromagnetic slide rails or screw slide rails are provided on both sides for driving the two laser cutting heads (120) and adhesive spraying heads (130) to move independently.

5. The modular sponge cushion fully automated flexible cutting and bonding production system according to claim 1, characterized in that, The rotating roller (430) is spindle-shaped. The worm gear groove (431) on the surface of the rotating roller (430) meshes with the worm gear rack (421) and drives the rotating roller (430) to roll during the rotation of the shaft (420).

6. The modular sponge cushion fully automated flexible cutting and bonding production system according to claim 1, characterized in that, The hub (410) is rotatably mounted on the inner side of the support base (300). The surface of the hub (410) is provided with a number of rotating grooves (412), and each of the rotating rollers (430) is rotatably mounted on the inner side of each rotating groove (412).

7. The modular sponge cushion fully automated flexible cutting and bonding production system according to claim 1, characterized in that, The rollers (430) are divided into two groups. Each group of rollers (430) is evenly distributed on the surface of the hub (410) in a circumferential direction. The two groups of rollers (430) are distributed alternately on both sides of the hub (410).

8. The modular sponge cushion fully automated flexible cutting and bonding production system according to claim 1, characterized in that, The first drive motor (320) is used to drive the hub (410) to rotate, and the second drive motor (330) is used to drive the shaft (420) to rotate.

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