Spring Unit Manufacturing: Coil Interlinking and Jaw Actuation
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Solution Overview
Problem
The existing manufacturing processes for spring units, particularly in the production of upholstered articles like mattresses, are inefficient due to complex and unreliable machinery that requires precise control and is not adaptable to different coil sizes, leading to low operational efficiency and frequent interruptions.
Innovation Solution
The introduction of a coil formation apparatus with a pivotally disposed body and adjustable guide member controlled by a servomotor, and a coil interlinking process using compression and indexing members for sequential linear movements, simplifying the interlinking process and allowing for easier adjustment of coil pitch and size, along with a spring unit assembly machine using eccentric cams and linkage assemblies for binding coils with a helical binding wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional linking table with butterfly clamp and pecker arm is used for interlinking coils, then coil interlinking can be achieved, but the process is unduly complex and requires extremely accurate control of multiple simultaneous actions
Solution Approach 1:
The interlinking process is divided into distinct sequential steps: first compressing the first coil, then extending the second coil through the clearance, retracting the compression member, and finally retracting the indexing member. This segmentation of the complex simultaneous actions into separate sequential operations simplifies the control requirements and reduces apparatus complexity while maintaining reliability.
Solution Approach 2:
The patent uses movable compression members and indexing members that can be actuated in sequence to dynamically control the coil interlinking process. The compression member moves to compress coils, the indexing member extends and retracts to position coils, creating a dynamic system that adapts to the interlinking requirements without requiring complex fixed mechanisms.
2Manufacturing precision
If conventional linking table with multiple cammed surfaces is used for accurate control, then coil interlinking precision can be maintained, but operational efficiency is severely restricted to 30-35 coils per minute
Solution Approach 1:
The patent enables continuous operation by eliminating the need for complex cammed surfaces that require precise timing and coordination. The sequential actuation of compression members and indexing members allows for uninterrupted coil interlinking at higher speeds, maintaining precision through controlled sequential movements rather than complex simultaneous cam mechanisms.
Solution Approach 2:
The patent replaces the complex mechanical cammed surface system with a simpler actuation mechanism using compression members and indexing members that can be controlled more efficiently. This substitution of the mechanical control system enables higher operational speeds while maintaining the necessary precision for accurate coil interlinking.
3Ease of operation
If conventional assembly machine with double acting pneumatic pistons and sensors is used for jaw opening and closing, then jaw movement can be controlled, but machine operation is often interrupted through sensor malfunction
Solution Approach 1:
The patent removes the problematic sensors from the jaw actuation system. By using a mechanical linkage system driven by a single rotary drive shaft with cam mechanisms, the system eliminates the electronic sensors that were prone to malfunction and causing interruptions. The jaw opening and closing is achieved through direct mechanical control without sensor intervention.
Solution Approach 2:
The mechanical linkage system with cam mechanisms provides self-contained control of jaw movement without requiring external sensor feedback. The cam profiles inherently control the timing and sequence of jaw opening and closing, making the system self-regulating and eliminating reliance on external sensors that could fail and interrupt operation.
4Productivity
If conventional coiler with fixed component positions is used for coil formation, then coil production can be maintained, but adjustment of coil pitch is not possible without significant changes to relative positions of machine components
Solution Approach 1:
The patent introduces adjustable positioning mechanisms for the guide member and coiling head that allow dynamic reconfiguration of the coiling parameters. The guide member can be positioned at different locations, and the coiling head angle can be adjusted, enabling variable coil pitch and size without requiring significant changes to the overall machine structure or relative component positions.
Solution Approach 2:
The patent creates a universal coiling system where a single coiler apparatus can produce coils with different pitches and sizes by adjusting the guide member position and coiling head angle. This multi-functional capability allows the same machine to accommodate various coil specifications without requiring multiple dedicated coilers or major structural modifications.
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
This approach significantly increases the throughput of coil interlinking, doubles operational efficiency, and allows for easier adjustment and reliability in manufacturing spring units, reducing the complexity and reliability issues of previous methods.
Implementation Method 1
the angle of pivotal movement of the guide member being controlled by an adjustable drive mechanism that comprises a rotary drive shaft driven by a servomotor
Implementation Method 2
actuating a first compression member to compress the first coil substantially parallel to said first coil axis to define a first clearance
Implementation Method 3
actuating a first indexing member to extend the second coil substantially parallel to said longitudinal axis passed the first coil via said first clearance
Implementation Method 4
The jaws are actuated by a cam and linkage assembly
Data Source
AI summary
Apparatus and methods for use in the manufacture of a spring unit for incorporation into an upholstered article, for example, a mattress, cushion or the like. Coil formation apparatus includes a drive shaft used to control movement of a coil pitch guide member and a link member comprising a connecting rod connected to a radius arm of the drive shaft by means of an adjustable connection. A coil interlinking process comprises compressing a first coil to define a clearance extending a second coil passed the first coil via the clearance, allowing the first coil to extend across the clearance, and contracting the second coil such that the second coil engages the first coil thereby interlinking the first and second coils. Spring unit manufacturing apparatus comprises a plurality of jaw pairs each comprising a first fixed jaw and a pivotal second jaw, the pivotal second jaw being pivoted by a cam and linkage assembly that is operated by a rotary drive shaft.