Automatic assembly line for mattress spring
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Solution Overview
Problem
Conventional automation equipment for mattress spring assembly is limited in functionality, requiring manual operations such as frame loading, non-woven fabric folding, and butterfly spring nailing, which affects assembly efficiency and accuracy.
Innovation Solution
An automatic assembly line comprising a mattress spring conveying mechanism, frame assembly mechanism, non-woven fabric folding assembly, and butterfly spring nailing mechanism, which includes components like clamping modules, folding plates, and nailing assemblies to automate the process of frame installation, non-woven fabric folding, and butterfly spring nailing on mattress springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional automation equipment is used for mattress spring assembly, then basic assembly functions are provided, but manual operations are still required for frame loading, non-woven fabric folding, and butterfly spring nailing
Solution Approach 1:
The assembly line is divided into distinct functional modules: frame loading assembly with bin and guide, non-woven fabric folding assembly with folding plate, and butterfly spring nailing assembly with positioning and nailing devices. Each module handles a specific task independently, enabling full automation while keeping each subsystem manageable in complexity
Solution Approach 2:
Multiple assembly operations are combined into a single integrated automated assembly line that performs frame installation, non-woven fabric folding, and butterfly spring nailing in sequence without manual intervention, achieving high automation by merging previously separate manual or semi-automated processes
2Productivity
If manual operations are used for frame loading and non-woven fabric folding, then equipment complexity is reduced, but assembly efficiency decreases
Solution Approach 1:
Frames are pre-positioned in the bin for automated picking, and the non-woven fabric is pre-placed on the mattress spring before the folding operation. This preliminary preparation enables the automated equipment to perform only the critical assembly actions, improving efficiency without requiring excessively complex equipment
Solution Approach 2:
The folding plate automatically folds the non-woven fabric edge over the frame without manual assistance, and the positioning assembly automatically positions the mattress spring for butterfly spring installation. The system performs these operations autonomously, improving assembly efficiency while maintaining reasonable equipment complexity
3Manufacturing precision
If manual holding of nail gun is required for butterfly spring nailing, then operation flexibility is maintained, but assembly accuracy and consistency are reduced
Solution Approach 1:
The manual nail gun operation is replaced with an automated nailing device that is precisely positioned by the positioning assembly. This mechanical substitution eliminates manual variability and achieves consistent, high-precision butterfly spring attachment while the automated system handles the operational complexity
4Productivity
If automated assembly is implemented for all operations, then assembly efficiency and accuracy are improved, but device complexity increases
Solution Approach 1:
The automated assembly line uses universal components and standardized fixtures that can handle multiple operations. The positioning assembly, for example, serves both to position the mattress spring for frame installation and to position it for butterfly spring nailing, reducing overall equipment complexity while maintaining high automation and efficiency
Data Source
AI summary
An automatic assembly line for mattress spring, includes a mattress spring conveying mechanism for conveying mattress springs; It also comprises a mattress spring frame assembly mechanism for installing frames on the mattress spring; It also comprises a mattress spring butterfly spring nailing mechanism for installing butterfly springs on the side of the mattress spring; This proposal designs an automatic assembly line for mattress spring, wherein the mattress spring frame assembly mechanism can automatically complete the loading of the frame, the transportation of the mattress spring frame assembly mechanism, the installation between the mattress spring and the frame, and the folding of non-woven fabric after the installation of the mattress spring frame.