Rotary Spring Transfer Wheel for High-Speed Pocketing Capture
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for transferring springs from a spring forming station to a pocketing station in the manufacture of pocketed spring units are inefficient, lacking a reliable and high-speed mechanism to capture and convey springs accurately.
Innovation Solution
A transfer apparatus comprising a conveyor with spaced-apart belts and a placement member with spring chambers that rotate to pass between the belts, capturing the springs and conveying them efficiently to the pocketing station. The apparatus includes a magnetic base for retaining springs and a compression portion to axially compress the springs before capture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If existing transfer methods are used, then the transfer process is simple, but the transfer rate is low and efficiency is poor
Solution Approach 1:
The placement member is designed to rotate continuously to dynamically deliver springs to the conveyor belts, replacing static transfer methods. This rotational mechanism enables high-speed continuous transfer while maintaining controlled spring placement through the interaction between the rotating chambers and moving belts
Solution Approach 2:
The placement member acts as an intermediary component between the spring forming station and the conveyor system. It receives springs from the forming station, temporarily holds them in rotating chambers, and delivers them to the conveyor belts, enabling efficient transfer without direct contact between the forming station and conveyor
2Reliability
If springs are captured between moving belts, then accurate capture is achieved, but reliable high-speed capture is difficult
Solution Approach 1:
The conveyor belts perform preliminary action by moving into position between the chambers of the placement member before the springs are delivered. This pre-positioning ensures that the belts are ready to immediately capture springs as they are deposited, enabling high-speed reliable capture without waiting or adjustment delays
Solution Approach 2:
The magnetic base replaces traditional mechanical spring holding mechanisms. By using magnetic force to retain springs in the chambers during rotation, the system achieves more reliable spring retention at higher speeds compared to mechanical clamps or holders, which would require complex actuation and adjustment mechanisms
3Manufacturing precision
If spring chambers rotate to pass between belts, then accurate conveyance is achieved, but the mechanism becomes complex
Solution Approach 1:
The placement member is segmented into multiple discrete chambers arranged around its circumference. Each chamber independently holds and delivers a single spring, allowing precise control of spring placement. This segmentation enables accurate spring-by-spring conveyance while keeping each chamber structurally simple
Solution Approach 2:
The rotating placement member performs multiple functions: it receives springs from the forming station, temporarily stores them in rotating chambers, delivers them to the conveyor belts, and maintains spring orientation. This multi-functionality in a single component reduces overall system complexity compared to using separate devices for each function
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 apparatus significantly enhances the rate of spring transfer from the forming station to the pocketing station, ensuring accurate capture and conveyance of springs, thereby improving the production efficiency of pocketed spring units.
Implementation Method 1
The magnetic base may be arranged in use to retain the spring such that the spring axis is substantially parallel with the rotation axis of the placement member
Implementation Method 2
the compression portion comprises a pair of spaced compression members between which the spring is arranged to pass as the placement member rotates. The compression members may be arranged to converge in the direction of movement of the spring
Implementation Method 3
the spring is captured by the belts
Data Source
AI summary
A spring transfer apparatus is shown generally at 1000. The apparatus comprises a wheel-like placement member 1100 which, in use, is driven to rotate in the direction of Arrow A1 about a central hub 1110 by a motor (not shown). The placement wheel 1100 has a plurality of circumferentially spaced spoke portions 1120 defining therebetween a series of spring chambers 1130. A magnetic base plate 1200 is arranged beneath the wheel 1100 and is arranged to receive a coil spring S which is deposited by a spring forming apparatus (not shown) of a known type, located above the plate 1200. As the wheel rotates, the spring is urged by the spokes 1120 along the magnetic base plate 1200 towards an arcuate compression stage 1300, comprising a pair of plates 1310 and 1320 that are axially spaced above and below the spring. The plates initially converge in a chamfer in the direction of rotation of the wheel 1100 causing the springs to become partly axially compressed as they transit between the plates. As the springs exit the plates, they are urged by the spokes into positions between a pair of superposed driven endless belts 1410 and 1420 between which the springs are further compressed and then conveyed to a pocketing station (not shown) where they are inserted into pockets for incorporation into a resilient spring unit, such as for use in a mattress core. The belts are optionally castellated to maintain a good grip of the springs.