Multi-Head Coiler System for Parallel Pocketed Spring Production
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Solution Overview
Problem
Conventional mattress assembly systems are bottlenecked by the slow production rate of strings of pocketed coils, as they typically operate on a single spring coil at a time, failing to keep up with the assembler's processing speed.
Innovation Solution
A multi-head coiler system that simultaneously produces, transports, compresses, and inserts multiple spring coils between fabric plies, using multiple coilers, a spring transporter, compressor, inserter, welders, and expander to create pocketed coils efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single spring coiler is used to produce pocketed coils, then the device complexity is low, but the productivity is insufficient and becomes the bottleneck of the manufacturing process
Solution Approach 1:
The system divides the coil production process into multiple independent coiler heads (first spring coiler, second spring coiler, etc.), each capable of producing coils simultaneously. This segmentation allows parallel production while keeping each individual coiler head relatively simple in structure.
Solution Approach 2:
Multiple coiler heads are merged into a single integrated system that shares common components such as the fabric feed mechanism, welding system, and controller. This combining approach increases productivity while avoiding the full complexity of having completely separate production lines.
2Productivity
If multiple spring coilers operate simultaneously, then the productivity increases, but the device complexity increases due to multiple components
Solution Approach 1:
The system employs universal components that serve multiple functions across different coiler heads. For example, a single fabric feed mechanism supplies material to multiple coilers, and the welding system can weld coils from multiple heads simultaneously, reducing overall system complexity despite increased productivity.
Solution Approach 2:
The system transitions from sequential single-head operation to parallel multi-head operation, adding a dimensional aspect of simultaneity. Multiple coilers work in parallel along the fabric width, transforming the production process from a one-dimensional sequential operation to a two-dimensional parallel operation.
3Productivity
If conventional single-coil processing is used, then the ease of operation is maintained, but the productivity is too slow to keep up with the assembler
Solution Approach 1:
The system incorporates automated functions where the controller automatically coordinates the operation of multiple coiler heads, fabric feeding, welding, and coil handling. This self-service automation maintains ease of operation by reducing manual intervention while dramatically increasing productivity through parallel processing.
Solution Approach 2:
The system ensures continuous operation of all coiler heads simultaneously, with no idle time between coil productions. The fabric feed mechanism continuously supplies material to all heads, and the welding system continuously welds coils as they are formed, maintaining uninterrupted productive action across all stations.
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 increases the production rate and efficiency of pocketed coils, allowing for faster and more efficient manufacturing of mattress assemblies by processing multiple coils simultaneously.
Implementation Method 1
Each of the at least two spring coilers can be configured to simultaneously produce a spring coil
Implementation Method 2
The spring compressor can be configured to simultaneously compress the at least two spring coils
Implementation Method 3
The first welder can be configured to weld an edge of the folded fabric parallel to the longitudinal axis of the fabric
Implementation Method 4
The spring expander can be configured to expand each of the compressed spring coils within the plurality of pockets
Data Source
AI summary
A system for manufacturing a string of pocketed coil springs comprising: a coil-forming subsystem that produces two coil springs; a spring transporter subsystem that receives the two coil springs at a first position and conveys the two coil springs to a second position; a spring compressor subsystem that compresses the two coil springs; a fabric-folding subsystem that receives a piece of fabric and folds the fabric to create an open side; a spring inserter subsystem that receives the two compressed coil springs and inserts the two compressed coil springs between top and bottom surfaces of a folded piece of fabric; two welder subsystems that form first and second welds between top and bottom surfaces of the folded piece of fabric, the first welds and the second welds forming a plurality of pockets in the fabric, each of the plurality of pockets comprising a compressed coil spring.