Box spring assembly system
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing box spring assembly systems require user input to determine the size of the box spring being assembled, leading to increased assembly time as individual components need to be adjusted accordingly.
Innovation Solution
A box spring assembly system with a platform featuring a conveyor belt and a carriage equipped with firing mechanisms, controlled by an electronic unit, automatically detects the size of the base unit, positions the firing mechanisms, and moves the base unit and wire grid between receiving areas to assemble the box spring without user input, allowing a second box spring to be staged concurrently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If user input is required to determine box spring size, then the system can accommodate specific box spring dimensions, but assembly time increases due to manual adjustments
Solution Approach 1:
The system automatically detects the size of the base unit using sensors and electronic control, eliminating the need for user input. The electronic control unit receives sensor data about the base unit dimensions and automatically adjusts the firing mechanisms positioning, allowing the system to serve itself rather than requiring manual operation.
Solution Approach 2:
The patent replaces manual mechanical adjustment with an electronic detection and control system. Sensors detect base unit size, and an electronic control unit processes this information to automatically position the firing mechanisms, substituting the mechanical system of manual measurement and adjustment with an electronic automation system.
2Manufacturing precision
If the system assembles only one box spring at a time, then assembly precision can be maintained, but productivity decreases
Solution Approach 1:
The system stages components for a second box spring in advance while the first box spring is being assembled. The conveyor belt positions and the firing mechanisms are prepared for the next assembly operation beforehand, allowing continuous production without sacrificing the precision achieved during the first assembly cycle.
Solution Approach 2:
The patent enables continuous assembly operations by having a second box spring staged and ready while the first is being assembled. The conveyor belt and firing mechanisms transition smoothly between assembly cycles without idle time, maintaining continuous useful action while preserving assembly precision through the automated control system.
Data Source
AI summary
A box spring assembly system includes a platform including a first box spring receiving area and a second box spring receiving area, the platform including a conveyor belt for moving a base unit and a wire grid from the first box spring receiving area to the second box spring receiving area, a carriage, the carriage including a plurality of firing mechanisms, and an electronic control unit configured to determine a size of the base unit positioned within the first box spring receiving area, position the plurality of firing mechanisms based on the detected size of the base unit, instruct the firing mechanisms to secure the wire grid to the base unit, and instruct the conveyor belt to move the base unit and the wire grid from the first box spring receiving area to the second box spring receiving area.