Spring Transfer Wheel With Magnetic Alignment and Belt Capture
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Solution Overview
Problem
Existing methods for transferring springs in the manufacture of pocketed spring units are inefficient and require manual intervention, limiting production efficiency.
Innovation Solution
A conveyor system with a rotating placement member having spring chambers that temporarily retain springs, which are then captured by moving belts for transfer from a spring forming station to a pocketing station, utilizing a magnetic base for alignment and axial compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual intervention is used to transfer springs, then ease of operation is maintained, but productivity is limited
Solution Approach 1:
The placement member automatically captures springs from the spring coiler and delivers them to the conveyor belt without manual intervention. The system serves itself by using the rotational motion of the placement member to transfer springs, eliminating the need for operators to manually handle each spring while maintaining continuous operation.
Solution Approach 2:
The placement member acts as an intermediary device between the spring coiler and the conveyor belt. It temporarily holds springs in its chambers and uses its rotation to transfer them to the moving belts, which then convey the springs to the pocketing station. This intermediary mechanism enables automated transfer without direct manual handling.
2Productivity
If continuous operation is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The placement member is divided into multiple spring chambers arranged around its periphery, allowing it to hold and transfer multiple springs in sequence. This segmentation enables continuous operation as different chambers are at different stages of the transfer cycle, with one chamber capturing a spring while another delivers it to the conveyor, eliminating idle time between transfers.
Solution Approach 2:
The placement member rotates continuously to transfer springs, rather than stopping and starting for each transfer. This dynamic rotational motion allows the system to maintain continuous operation, with the placement member constantly moving between the spring coiler and the conveyor belt, transferring springs in an unbroken sequence.
3Manufacturing precision
If spring capture by moving belts is used, then manufacturing precision is improved, but force requirements increase
Solution Approach 1:
The placement member pre-positions springs in its chambers with the spring axis aligned parallel to the rotation axis before transfer. This preliminary alignment ensures that when the spring is released onto the moving conveyor belts, it is already in the correct orientation and position, allowing the belts to capture and convey the spring accurately without requiring excessive force for positioning.
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
Enhances the transfer rate of springs, allowing continuous operation and improved production efficiency in manufacturing pocketed spring units.
Implementation Method 1
The apparatus comprises a magnetic base beneath the placement member. 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 members may be arranged to converge in the direction of movement of the spring and preferably comprise a pair of plates.
Implementation Method 3
The conveyor comprises a pair of superposed belts configured to convey the spring from the spring forming station to the pocketing station.
Data Source
Figure 1~2
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.