Foundation Truss Rail Assembly for Automated Alignment and Fastening
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Solution Overview
Problem
The manual and semi-automatic processes in manufacturing box spring or foundation frame components are labor-intensive and limit production speeds, increasing labor costs and requiring substantial manual interaction for alignment and fastening operations.
Innovation Solution
A system and method for substantially automated formation of trusses for foundation or box spring frames, utilizing a first and second truss rail assembly station linked by a conveyor, with adjustable assembly conveyors, pusher rails, and actuated pusher blocks to align and secure wooden components, followed by automatic fastening using staplers or nail guns, enabling efficient transfer and assembly of trusses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual processes are used to align and assemble foundation pieces in a jig, then workers can position components, but production speed is limited and labor costs increase
Solution Approach 1:
The system uses self-aligning features where the rail and block components have built-in alignment mechanisms that automatically position pieces correctly during feeding, eliminating the need for manual alignment by workers while maintaining assembly accuracy
Solution Approach 2:
The patent replaces manual mechanical alignment operations with an automated feeding system that uses conveyors, pusher blocks, and alignment guides to mechanically position components, thereby increasing production speed while reducing labor requirements
2Extent of automation
If semiautomatic equipment is introduced to manufacture foundation frame components, then some automation is achieved, but substantial manual interaction is still required for loading and alignment
Solution Approach 1:
The hoppers are designed to automatically feed blocks and rails onto the conveyor system without manual intervention. The blocks slide down gravity-fed chutes and are automatically positioned by pusher blocks, while rails are fed from hoppers and aligned by guide rails, creating a self-servicing system that minimizes operator involvement
Solution Approach 2:
Components are pre-positioned and stored in hoppers before assembly begins. The system performs preliminary alignment actions through fixed guides and pusher mechanisms that automatically orient blocks and rails correctly before they reach the assembly point, eliminating the need for manual preparation
3Productivity
If semiautomatic equipment is used for fastening operations, then some fastening can be automated, but operator intervention is still needed to ensure proper alignment before fastening
Solution Approach 1:
The patent replaces manual alignment verification with automated mechanical alignment systems. Fixed alignment guides, precision-machined surfaces, and guided pusher blocks ensure that components are correctly positioned before fastening occurs, maintaining manufacturing precision while enabling automated high-speed fastening operations
Solution Approach 2:
The invention introduces intermediary alignment fixtures and guide structures between the component feeding system and the fastening mechanism. These intermediaries ensure proper alignment by physically constraining components in correct positions, allowing the fastening system to operate automatically without operator intervention while maintaining precision
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system significantly reduces labor costs and increases production speed by automating the alignment and fastening of trusses, allowing for efficient formation and transfer of completed trusses for further assembly into foundation frames, enhancing manufacturing efficiency.
Implementation Method 1
a removable gravity conveyor, so that after a first truss portion
Implementation Method 2
a spring-loaded pusher for urging the blocks toward a discharge
Data Source
AI summary
A system and method for forming a foundation truss for a box spring or mattress foundation frame includes a first truss rail assembly station having a series of block feeders, a top rail hopper and a filler strip hopper that received stacks of truss components such as blocks, top rails and filler strips and feed such truss components into stacked registration. The stacked truss components are moved into engagement with a series of staplers that secure the filler strips, top rails and blocks together to form first truss rail portions, which are then fed to a second truss rail assembly station where a bottom rail is automatically applied thereto.