Multi-Head Coiler System for High-Speed Pocketed Spring Production
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Solution Overview
Problem
Conventional mattress assembly systems are bottlenecked by the slow production rate of pocketed coils, as they typically operate on a single spring coil at a time, failing to keep up with the assembler's speed in assembling mattress segments.
Innovation Solution
A multi-head coiler system that simultaneously produces and processes multiple spring coils, including a dual-coil configuration with independent coilers, a spring transporter, compressor, inserter, welders, and expander to efficiently create and assemble pocketed coils within fabric pockets.
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 a bottleneck in 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 unit relatively simple in design.
Solution Approach 2:
Multiple coiler heads are merged into a single integrated system that shares common components such as the fabric feed mechanism, compressor, inserter, welders, and expander. This combining approach increases productivity while avoiding the need for completely separate systems for each coiler.
2Productivity
If multiple spring coils are processed sequentially one at a time, then the device complexity remains low, but the production rate cannot keep up with the assembler's speed
Solution Approach 1:
The system enables continuous production by having multiple coiler heads operating simultaneously and continuously, eliminating idle time between coil productions. The fabric feed mechanism continuously supplies material to all coiler heads without interruption.
Solution Approach 2:
Multiple coils are prepared in advance by the multiple coiler heads before being transported to the assembler. This preliminary parallel production ensures that coils are ready ahead of time to keep the assembler continuously working without waiting.
3Productivity
If a single coiler produces all coils, then the system is simple to operate, but it cannot meet the high-speed assembly requirements
Solution Approach 1:
The system uses multiple coiler heads that are identical in function and operation, allowing the operator to control them in a uniform manner. Each head performs the same multi-functional process of forming, compressing, inserting, welding, and expanding coils, maintaining operational simplicity despite increased capacity.
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 mattress assembly by processing multiple coils simultaneously, addressing the bottleneck in conventional systems.
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 transporter can be configured to simultaneously receive the at last two spring coils produced by the spring coilers and transport the at least two spring coils
Implementation Method 3
The spring compressor can be configured to simultaneously compress the at least two spring coils
Implementation Method 4
The first welder can be configured to weld an edge of the folded fabric parallel to the longitudinal axis of the fabric and opposite the folded edge of the fabric to join the top and bottom fabric plies
Implementation Method 5
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.