Mattress Forming Machine with Variable Rotation Processing Cylinders
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Solution Overview
Problem
Existing machines for forming mattresses or panels from non-solid materials are limited in their ability to produce varying products from the same starting material, as they can only perform a single processing operation, necessitating the use of multiple machines to meet diverse market demands.
Innovation Solution
A machine with multiple processing stations, including a loading station, processing cylinders, a pressing station with counter-rotating conveyor belts, and a heating station, which allows for different processing configurations by adjusting the rotation direction of the main processing cylinder and utilizing additive materials to achieve varying densities and thicknesses, enabling the production of multiple products from the same non-solid material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single processing station with fixed rotation direction is used, then the machine structure is simple, but the adaptability to produce different mattress types is poor
Solution Approach 1:
The main processing cylinder is designed with variable rotation direction capability, allowing it to rotate in first direction for initial processing and second direction for additional processing. This dynamic change in rotation direction enables a single machine to produce different mattress types (softer with lower density or firmer with higher density) without requiring multiple dedicated machines, thus improving adaptability while maintaining relatively simple structure.
2Manufacturing precision
If the processing cylinder rotates in a single direction, then the processing operation is simple, but the product density and thickness variations are limited
Solution Approach 1:
The system allows the main processing cylinder to dynamically switch rotation directions based on the desired product specifications. Rotating in the first direction produces mattresses with lower density and higher thickness, while rotating in the second direction produces mattresses with higher density and lower thickness. This dynamic control enables precise manufacturing precision for density and thickness variations using the same processing equipment.
3Adaptability or versatility
If multiple dedicated machines are used for different products, then the manufacturing precision for specific products is high, but the production cost increases
Solution Approach 1:
The machine is designed as a universal processing system where the main processing cylinder can perform multiple functions by changing rotation direction. The same machine can produce different mattress types (softer or firmer) that previously required separate dedicated machines. This multi-functionality reduces the total number of machines needed, lowering production costs while maintaining the ability to manufacture various product types with appropriate quality standards.
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 machine can perform at least two different processing operations with the same non-solid starting material, enhancing adaptability to market requirements and reducing the risk of material breakages or tears by optimizing the forming path angles, thus optimizing the production process for diverse products.
Implementation Method 1
a station for heating the mattress or panel being formed
Implementation Method 2
a pressing station for imparting a preset density and a predetermined final thickness to the mattress at the outlet
Implementation Method 3
a minimum part of adhesive material designed to make the fibrous or flock material cohesive and solid
Data Source
Figure 1
Figure 2
AI summary
Described is a machine (1) for forming mattresses or panels from non-solid material comprising a loading station (2), a processing station (3) operatively connected to said loading station (2) and comprising a first processing cylinder (31), said processing station (3) also comprising a second processing cylinder (32), a pressing station (4) positioned downstream of said processing station (3) and comprising two conveyor belts (41, 42) counter-rotating along an advancement direction (A) .