Index Wheel Feed Mechanism for Precise Pocketed Spring Spacing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need for techniques that allow for efficiently and precisely feeding pocketed spring strands into a pocketed spring assembly machine, which is essential for forming innerspring units in mattresses and other furniture, as existing methods lack precision and efficiency.
Innovation Solution
A feed mechanism utilizing an index wheel with rotatable support members and a Cardan joint mechanism, coupled with a belt drive, allows for precise positioning and spacing of pocketed springs by adjusting the rotation axes and using multiple index wheels to convey the strands between conveyor belts, ensuring precise alignment and spacing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple conveyor system is used to feed pocketed spring strands, then the device complexity is reduced, but the positioning precision and spacing accuracy of individual springs deteriorate
Solution Approach 1:
The feed mechanism is segmented into multiple independent index wheels, each responsible for engaging and positioning specific pockets of the spring strand. Each index wheel has individually adjustable blades that can be tilted and positioned independently, allowing precise control over spring spacing and positioning without requiring a completely complex integrated system.
Solution Approach 2:
The index wheels incorporate dynamically adjustable components including tiltable blades and movable support members that can be adjusted during operation. The parallel shift between rotation axes can be modified to accommodate different spring diameters, providing adaptability without permanent system reconfiguration.
2Device complexity
If fixed spacing blades are used on the index wheel, then the device complexity is reduced, but the adaptability to different spring diameters deteriorates
Solution Approach 1:
The index wheel features dynamically adjustable blades that can be tilted and repositioned along the circumference. The support members holding the blades can be moved radially and angularly, allowing the spacing between blades to be adjusted to match different spring diameters while maintaining a relatively simple base structure.
Solution Approach 2:
The system allows changing of geometric parameters including blade spacing, blade tilt angle, and rotation axis offset. These parameter adjustments enable the same index wheel structure to accommodate various spring diameters and pocket configurations without requiring multiple specialized wheels.
3Adaptability or versatility
If multiple index wheels with adjustable rotation axes are used to accommodate various spring diameters, then the adaptability is improved, but the device complexity increases
Solution Approach 1:
The index wheel assembly serves multiple functions: it conveys the spring strand, positions individual springs, adjusts spacing, and adapts to different diameters. The same basic structure with adjustable support members and tiltable blades handles various spring configurations, reducing the need for entirely separate mechanisms for each function.
Solution Approach 2:
The adjustable support members and tiltable blades are nested within the index wheel structure in a compact arrangement. The Cardan joint mechanism is integrated within the support member assembly, allowing complex adjustments to be achieved through nested, space-efficient component placement.
4Manufacturing precision
If precise positioning mechanisms with tiltable blades are used, then the manufacturing precision is improved, but the ease of operation deteriorates
Solution Approach 1:
The tiltable blades and adjustable support members are designed to be self-adjusting through the mechanical action of the rotating index wheel itself. As the wheel rotates and engages with the spring strand, the blades automatically tilt and position themselves relative to the spring pockets, reducing the need for manual fine-tuning during operation.
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 feed mechanism enables precise and efficient feeding of pocketed spring strands, accommodating various spring diameters and improving the assembly process by ensuring accurate alignment and spacing, thereby enhancing the overall efficiency of the pocketed spring assembly machine.
Implementation Method 1
the index wheel may further comprise a Cardan joint mechanism coupling the first support member and the second support member
Implementation Method 2
a first support element which supports a shaft element of the blade to be tiltable about a tilt axis extending in parallel to the first rotation axis
Implementation Method 3
a second support element which is slidable along the shaft element and supports the shaft element of the blade to be tiltable the said tilt axis
Data Source
AI summary
A feed mechanism for pocketed spring strands is provided with at least one index wheel having a plurality of blades. The feed mechanism is provided with a motor. The at least one index wheel includes a first support member which is rotatable about a first rotation axis and carries a first support element which supports a shaft element of the blade to be tiltable about a tilt axis extending in parallel to the first rotation axis. The at least one index wheel includes a second support member which is rotatable about a second rotation axis which extends in parallel to the first rotation axis and carries a second support element which is slidable along the shaft element of the blade and supports the shaft element to be tiltable about the tilt axis.