Pocketed Spring Unit Production with Conveyor Feeding and Sequential Welding
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Solution Overview
Problem
Existing methods for producing pocketed spring units are overly complicated and costly, necessitating a more efficient and cost-effective approach.
Innovation Solution
A method and apparatus that compress and feed springs between opposed conveyor belts, moving them between fabric layers and sequentially welding the fabric to form discrete pockets containing the springs, using a spring coiler and power-driven inserter mechanisms for efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods are used to produce pocketed spring units, then the process can be completed, but the production is overly complicated and costly
Solution Approach 1:
The production process is divided into distinct sequential stages: spring formation, compression, feeding between conveyor belts, positioning between fabric layers, and welding. Each stage is handled by specialized components working in sequence, which simplifies the overall system design and makes each subsystem easier to manufacture and maintain while achieving high productivity
Solution Approach 2:
Traditional mechanical handling and positioning systems are replaced with a synchronized conveyor belt system that uses the movement and positioning of the belts themselves to transport and position springs and fabric layers. This reduces the need for complex mechanical manipulators and positioning mechanisms, thereby reducing device complexity
2Ease of manufacture
If traditional methods are used to produce pocketed spring units, then the process can be completed, but the production cost is high
Solution Approach 1:
The conveyor belts operate continuously, constantly transporting springs, fabric layers, and welded assemblies through the production line. The step-wise advancement mechanism ensures that welding operations are performed continuously on multiple pockets simultaneously as the material progresses through the system, eliminating idle time and maximizing productivity while maintaining cost-effectiveness
Solution Approach 2:
Springs are formed and compressed in advance before being fed into the conveyor system. The pre-compression of springs and pre-positioning of fabric layers prepare the components for immediate welding operations, eliminating the need for time-consuming on-line preparation and thereby increasing production efficiency without adding significant cost
3Manufacturing precision
If springs are manually placed between fabric layers, then positioning can be achieved, but the process is time-consuming and less precise
Solution Approach 1:
Manual spring placement is replaced with an automated conveyor-based positioning system. The conveyor belts are precisely controlled to move at synchronized speeds, and the step-wise advancement mechanism automatically positions springs and fabric layers in exact alignment. This mechanical substitution achieves high positioning precision while dramatically reducing placement time through continuous automated operation
Solution Approach 2:
The conveyor system is designed to automatically position and align springs with fabric layers through its inherent synchronized movement and step-wise advancement mechanism, without requiring external positioning devices or manual intervention. The system self-regulates the positioning through the coordinated motion of the belts and the fixed geometry of the troughs and castellations
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 solution simplifies and cost-reduces the production of pocketed spring units by enabling precise control and automation of the spring placement and welding process, resulting in a more efficient and scalable method for forming these units.
Implementation Method 1
welding means for sequentially welding together said lengths so as to form a plurality of discrete pockets each containing a spring
Data Source
AI summary
A method and apparatus for the production of a pocketed spring unit, the method comprising the steps of compressing and feeding a plurality of springs (42) into troughs (2A, 4A) or castellations in opposed conveyor belts (2, 4), moving said springs (42) from said troughs (2A, 4A) or castellations to a position between upper and lower layers of fabric or other material (16A, 18A), step-wise advancing said material (16A, 18A) and said springs (42) in the direction of the output of the apparatus and welding together said lengths of fabric or other material (16A, 18A) at each step-wise advancement by a plurality of sequentially controlled welding anvils (10) so as to form a plurality of discrete pockets (46) each containing a spring (42). Apparatus for carrying out the method is disclosed.