Machine and method

Abstract

A bed slat processing machine 100 and method of using the apparatus. The machine comprises an input hopper 102, into which bed slats for processing can be loaded. There are one or more processing stat

Description

28 07 25 TECHNICAL FIELD The present invention relates to a bed slat processing machine and a method of processing bed slats using the same. BACKGROUND Beds are typically made from a bed base, or foundation, that supports a mattress. One form of bed base is the slatted bed base, whereby wooden slats are placed across a frame widthways to support the user. The wooden slats are made either from solid pieces of wood, for example birch, beech, or pine, or from composite boards made up of layers of veneer which are glued together. These wooden slats must be processed before use, for example to include pre-drilled holes for attachment to the frame, to be deburred, and / or to include printed matter. The present invention was arrived at in light of the above considerations. SUMMARY In a first aspect, the present invention provides a bed slat processing machine, comprising: an input hopper, into which bed slats for processing can be loaded; one or more processing stations, located along a processing line, each configured to perform a process on a bed slat from the input hopper when located at the processing station; a conveying mechanism, configured to move bed slats loaded into the input hopper through the machine and along the processing line, to stop at the or each processing station; and an output hopper, into which the processed bed slats are loaded by the conveying mechanism after they have been processed at the one or more processing stations; wherein the machine includes first and second working platforms, along which at least one processing station is located, a distance between the first and second working platforms being adjustable; and wherein a deburring station comprises a set of two sanding wheels, one located on or adjacent to the first working platform and one located on or adjacent to the second working platform at a position aligned with the first, the distance between the set of sanding wheels being adjustable by adjusting the distance between the first and second working platform. Such a machine can process bed slats quickly, and produce uniform bed slats for use in flatback style beds. The input hopper and output hopper may be adjustable, so as to accommodate bed slats of differing lengths. The input and output hopper may be configured so that the slats are inserted with their long 28 07 25 axis (length direction) being transversal or perpendicular to the processing line. The input hopper may include two C-shaped members which face one another across the long axis so that inserted bed slats are held inside the C-shaped members. The output hopper may include two L-shaped members that face one another across the long axis so that the processed slats are held inside the L-shaped members. The distance between the C- and L-shaped members may be adjustable, so that bed slats of differing lengths can be accommodated. The bed slats may be loaded into the input hopper such that a wider flat face (the bed slats having a generally rectangular shape) is uppermost, as compared to a narrower flat face. There may be a plurality of processing stations, and the conveying mechanism may be configured to move bed slats loaded into the input hopper through each of the processing stations in sequence. Each processing station may be configured to process a single bed slat at a time, with the operations of the plurality of processing stations being carried out in parallel on respective bed slats. The one or more processing stations may include one or more of: a deburring station, a drilling station, and a stamping or printing station. There may be seven, and may only be seven, processing stations including: a pair of drilling stations, two pairs of deburring stations, and a stamping or printing station. The drilling stations may be configured to drill holes in or through a bed slat, and the pair of drilling stations may be configured to drill holes in or through a given bed slat at respectively opposite ends of the bed slat. The drilling stations may be configured to drill holes in or through the wider flat face of the bed slats, such that they can be easily screwed to a bed frame (and with a reduced risk of splitting the wood). The drilling stations may include a pressure applicator, configured to apply a pressure to the bed slat before drilling, so as to securely seat the bed slat. The deburring stations may each be configured to apply a sanding wheel to the bed slat being processed. The sanding wheel may be transversally aligned with the longitudinal axis of the bed slat. Where there are four deburring stations (two pairs), the sanding heads in a given pair may have the same angle of alignment relative to the longitudinal axis of the bed slat. The first pair may be configured then to sand the upper surface of the bed slat at a first end of the slat and the lower surface of the bed slat at a second end of the slat. The second pair may be at a different alignment angle to the first pair, such that they are configured to sand the lower surface of the bed slat at the first end of the slat and the upper surface of the bed slat at the second end of the slat. As above, the input and output hoppers may each include two facing complementary parts usable to hold a plurality of bed slats, where a respective part of each of the input and output hoppers are located on one of the first and second working platforms. Moving one of the working platforms thereby changes the maximum length of the bed slats which can be processed by the machine. The 28 07 25 first and second working platforms may be aligned with the processing line. The second working platform may be mounted on a linear rail. There may be a plurality of processing stations, which are spaced along the first and / or second working platform. A deburring station comprises a set of two sanding wheels, one located on or adjacent to the first working platform and one located on or adjacent to the second working platform at a position aligned (along the processing line direction) with the first, the distance between the set of sanding wheels being adjustable by adjusting the distance between the first and second working platform. The conveying mechanism may be a stroke drive system, configured to move each bed slat through the machine along the processing line in set increments. Such a drive system is robust, both mechanically and in terms of alignment of the bed slat at each processing station. The output hopper may include a slat lifter, configured to lift any bed slats within the output hopper and so allow a newly processed bed slat to be provided into the output hopper. In a second aspect, the present invention provides a method of processing bed slats using the bed slat processing machine of the first aspect, the method comprising: providing one or more bed slats into the input hopper; operating the conveying mechanism to move the or each bed slat through the machine so as to stop at the or each processing station; at the or each processing station, performing processing of the or each bed slat; and providing the or each processed bed slat into the output hopper. The method of the second aspect may include any one, or any combination insofar as they are compatible, of the optional features set out with reference to the first aspect. The invention also includes the combination of the aspects and preferred features described except where such a combination is clearly impermissible or expressly avoided. Further aspects of the present invention provide: a computer program comprising code which, when run on a computer, causes the computer to perform at least some of the steps of the method of the second aspect; a computer readable medium storing a computer program comprising code which, when run on a computer, causes the computer to perform at least some of the steps of the method of the second aspect; and a computer system programmed to perform at least some of the steps of the method ofthe second aspect. BRIEF DESCRIPTION OF THE DRA WINGS Fig. 1 shows a bed slat processing machine in perspective view; and Fig. 2 shows the bed slat processing machine in a side-on view. 28 07 25 DETAILED DESCRIPTION Aspects and embodiments of the present invention will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. Fig. 1 shows a bed slat processing machine 100 in perspective view. Broadly, the machine includes three transverse rails 101a, 101 b, and 101c which extend between two floor supports 103a and 103b. Sat atop these three transverse rails are first 112a and second 112b working platforms. In this example, the second working platform 112b is slidable along the transverse rails to as to adjust the distance between the first and second working platform. Numerous components are mounted on the first 112a and second 112b working platforms. First, in a processing line 105 going from one end of the machine to the other, is an input hopper 102. The input hopper is formed of two C-shaped projections, one mounted on each of the first and second working platforms. The C’s face one another, so as to define a receptacle for a bed slat. A portion of each projection adjacent to the working platforms is removed so that bed slats can exit the hopper into and along the processing line 105. The width of the C’s defines the width of the bed slats which can be processed, as the bed slats are loaded in wide side down (the bed slats having a generally rectangular cross-section). The bed slats are typically pre-cut to size. The bed slats are moved through the processing machine via a drive dog system, where individual drive dogs 107 are raised so as to engage a bed slat on a first side (nearest the entrance to the machine), and then moved along processing line 105 before lowering and leaving the respective bed slat at a next position in the machine. There is a first set of drive dogs attached to a first side fence 114a of the first 112a working platform, and a corresponding second set of drive dogs attached to a second side fence 114b of the second 112b working platform. The drive dogs are driven in sync by one or more motors, so as to move together through the machine. As such, bed slats loaded into the input hopper 102 are conveyed in a stepped manner through various processing stations to an output hopper 104. At each processing station, an individual bed slat is processed according to the role of that station. The processed bed slats are then loaded into the output hopper 104, which includes two L-shaped projections extending respectively from the first 112a and second 112b working platform. The output hopper 104 also includes a slat lifting mechanism, which lifts the bed slats already in the output hopper 104 so that a newly processed bed slat can be slid underneath. 28 07 25 Turning then to the processing stations, in this example, a first processing station includes a first drill unit 106a mounted on the first 112a working platform and a second drill unit 106b mounted on the second 112b working platform. These drill units are configured to drill holes through a bed slat which has been moved in line with them. The drill holes are provided such that when a bed is assembled using the bed slats, the installer can follow the pre-drilled holes with screws which minimises the risk of the bed slat splitting. The first and second drill units include a pressure applicator, configured to apply a pressure on the bed slat to seat it securely before being drilled. Next, a second processing station includes a first set of sanding heads 108a and 108b, one mounted on each of the first 112a and second 112b working platforms. The first sanding head 108a is configured to sand an upper portion of a bed slat at a first end, by being raised a higher distance relative to the first working platform than the second sanding head, and being angled down towards the first working platform. In use then, it can sand and / or deburr the upper end of a wooden bed slat. The second sanding head 108b is configured to sand a lower portion of the bed slat at a second end (opposite to the first), by being lower relative to the second working platform than the first sanding head and being angled up away from the second working platform. The first and second sanding heads are centred on respective sanding axes, which are parallel to one another but offset in a vertical direction. Next, a third processing station includes a second set of sanding heads 110a and 110b which are arranged complementary to the first, one mounted on each of the first 112a and second 112b working platforms. The complementarity between the first and second set of sanding heads is such that the bed slat is sanded I deburred on the remaining unsanded surfaces by the second set of sanding heads. For example, by the first sanding head 110a of the second pair being arranged to sand I debur the lower portion of the bed slat at the first end, by being lower relative to the first working platform than the first sanding head 108a of the first pair of sanding heads and angled up away from the first working platform. Similarly, the second sanding head 110b of the second pair is arranged to sand I debur the upper portion of the bed slat at the second end, by being higher off the second working platform than the second sanding head 108b of the first pair of sanding heads and being angled down towards the second working platform. In some embodiments, a further processing station is provided (not shown) which is a printing or stamping station. This is configured to print or stamp a logo, instructions, etc, onto one or more ends of the processed bed slat and on one or both sides of the processed bed slat. This printing or stamping station can be the last processing station, immediately before the output hopper 104. Once processed, the bed slat is loaded into the output hopper 104 in the manner discussed above. 28 07 25 Fig. 2 shows the bed slat processing machine 100 in a side-on view. This view shows more clearly the direction 202 in which the second 112b working platform can be moved relative to the first 112a. This allows for bed slats of varying lengths to be processed in batch, which increases the flexibility of the machine. The machine can either be controlled by a computer, or other processor, which activates the motors, drills, and sanding heads as required, or it can be controlled entirely mechanically. The motors would be activated and left to run, with timing mechanisms causing the drive dogs to engage, move, and disengage. Similarly, the drills can either be lowered to drill their respective holes under the control of a computer or processor, or may be controlled entirely mechanically. The sanding heads may be left on whilst the machine is in use, or may be pulsed to only activate when a bed slat is present in the respective processing station. While the disclosure has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the disclosure set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the disclosure. In particular, although the methods of the above embodiments have been described as being implemented on the systems of the embodiments described, the methods and systems of the present disclosure need not be implemented in conjunction with each other, but can be implemented on alternative systems or using alternative methods respectively. The features disclosed in the description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilised for realising the disclosure in diverse forms thereof. While the disclosure has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the disclosure set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the disclosure. 28 07 25 For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations. Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described. Throughout this specification, including the claims which follow, unless the context requires otherwise, the word “comprise” and “include”, and variations such as “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means for example + / -10%.

Claims

28 07 251. A bed slat processing machine, comprising:an input hopper, into which bed slats for processing can be loaded;one or more processing stations, located along a processing line, each configured to perform a process on a bed slat from the input hopper when located at the processing station;a conveying mechanism, configured to move bed slats loaded into the input hopper through the machine and along the processing line, to stop at the or each processing station; andan output hopper, into which processed bed slats are loaded by the conveying mechanism after they have been processed at the one or more processing stations; whereinthe machine includes first and second working platforms, along which at least one processing station is located, a distance between the first and second working platforms being adjustable; andwherein a deburring station comprises a set of two sanding wheels, one located on or adjacent to the first working platform and one located on or adjacent to the second working platform at a position aligned with the first, the distance between the set of sanding wheels being adjustable by adjusting the distance between the first and second working platform.

2. The bed slat processing machine of claim 1, wherein the input hopper and output hopper are adjustable, to accommodate bed slats of differing lengths.

3. The bed slat processing machine of claim 1, wherein there are a plurality of processing stations, and the conveying mechanism is configured to move bed slats loaded into the input hopper through each of the processing stations in sequence.

4. The bed slat processing machine of any preceding claim, wherein the one or more processing stations include one or more of: a deburring station; a drilling station; and a stamping or printing station.

5. The bed slat processing machine of any preceding claim, wherein there are seven processing stations including: a pair of drilling stations; two pairs of deburring stations; and a stamping or printing station.28 07 256. The bed slat processing machine of claim 1, wherein the second working platform is mounted on a linear rail.

7. The bed slat processing machine of claim 6 or 7, wherein a plurality of processing stations are spaced along the first and / or second working platform.

8. The bed slat processing machine of any preceding claim, wherein the conveying mechanism is a stroke drive system, configured to move each bed slat through the machine along the processing line in set increments.

9. The bed slat processing machine of any preceding claim, wherein the output hopper includes a slat lifter, configured to lift any bed slats within the output hopper and so allow a newly processed bed slat to be provided into the output hopper.

10. A method of processing bed slats using the bed slat processing machine of any preceding claim, the method comprising:providing one or more bed slats into the input hopper;operating the conveying mechanism to move the or each bed slat through the machine so as to stop at the or each processing station;at the or each processing station, performing processing of the or each bed slat; and providing the or each processed bed slat into the output hopper.

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