Machine and method for assembling a bedding foundation
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Solution Overview
Problem
Existing methods for assembling bedding foundations, particularly fastening spring modules to a wooden frame, lack efficiency and precision, leading to manual errors and inconsistencies in the assembly process.
Innovation Solution
A machine with a vision-guided control system and movable staplers, where cameras provide visual guidance for the controller to direct the movement and stapling of spring modules onto the frame, ensuring accurate alignment and spacing, and actuators enable independent movement and pivoting of staplers for precise attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual methods are used for assembling bedding foundations, then device complexity is reduced, but manufacturing precision and productivity deteriorate due to manual errors and inconsistencies
Solution Approach 1:
The patent replaces manual mechanical assembly with an automated vision-guided system. Cameras capture images of the frame and spring modules, the controller processes these images to determine precise positions, and actuators automatically adjust stapler positions and perform fastening. This substitution of manual mechanical operations with automated vision-and-actuation systems directly achieves high alignment precision while accepting increased device complexity.
Solution Approach 2:
The vision system creates a digital copy (image) of the physical frame and spring module arrangement. The controller uses this optical copy to determine positions and guide the staplers without requiring complex physical measurement devices. This copying approach simplifies the control system while achieving high precision through image processing.
2Productivity
If automated stapling systems are used, then productivity is improved, but device complexity increases due to multiple actuators and control systems
Solution Approach 1:
The controller serves multiple functions: it receives images from cameras, processes these images to determine positions of the frame and spring modules, calculates required stapler positions, controls actuators for positioning, and triggers fastening operations. This multi-functionality consolidates what could be separate complex systems into a single controller, improving productivity while managing device complexity.
Solution Approach 2:
The system uses its own camera images to automatically determine positions and guide the staplers without requiring external measurement devices or manual intervention. The vision system and controller work together in a self-contained manner to achieve high-speed automated assembly with controlled complexity.
3Manufacturing precision
If fixed-position staplers are used, then device complexity is reduced, but manufacturing precision deteriorates due to inability to adapt to position variations
Solution Approach 1:
The staplers are made dynamically adjustable through actuators that can move each stapler to a calculated target position based on real-time image analysis. This dynamic positioning capability allows the system to adapt to variations in frame and spring module positions while maintaining high fastening accuracy, accepting the increased mechanism complexity of movable staplers with actuators.
Solution Approach 2:
The system changes the position parameter of each stapler dynamically based on image analysis results. Instead of fixed positions, the target position for each stapler is calculated from the captured images and adjusted accordingly. This parameter change approach enables high fastening accuracy while the complexity is managed through software-based position calculation rather than complex mechanical adjustment mechanisms.
Data Source
AI summary
An apparatus for assembling a bedding foundation having spring modules and a frame includes a support configured to receive the frame, a bridge disposed over the support, and staplers movably coupled to the bridge and positioned over the support, each stapler configured to staple a spring module to the frame. The apparatus also includes cameras coupled to the bridge and positioned over the support. Each stapler is operatively associated with one of the cameras and each camera is positioned to provide a field of view toward the support. The apparatus also includes a driver configured to move the frame relative to the support and a controller in communication with the cameras and the driver, the controller configured to receive vision guidance signals from one of the cameras to direct movement of the driver and of the stapler operatively associated with the one of the cameras.