Station for detecting, controlling, checking and comparing physical parameters of a mattress, a pillow and the like

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Solution Overview

Problem

The industrial production of mattresses and pillows faces imprecision in geometric and structural parameters due to variable raw materials and deformability, leading to inconsistent product dimensions and quality, making manual measurement time-consuming and costly, and prone to variability based on technician expertise.

Innovation Solution

A station comprising a retention frame with abutment walls and aligned rangefinders for automatic measurement of mattresses and pillows, including a roller conveyor and load cells to detect dimensions, weight, and deformability, enabling rapid and precise data collection without significant cost increase.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual measurement is used, then flexibility and low cost are maintained, but measurement precision and consistency deteriorate

Engineering Contradiction:

Improvemeasurement precisionVSAvoiddevice complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces manual mechanical measurement with an automated optical measurement system using a rangefinder. The rangefinder automatically measures the dimensions of mattresses and pillows by emitting and receiving light signals, eliminating the need for manual intervention while providing consistent and precise measurements.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The measurement system is designed to automatically perform measurements without requiring operator expertise. The rangefinder and control unit work together to autonomously capture dimensional data, making the measurement process independent of technician skill levels and ensuring uniformity across different operators and time periods.

Inventive Principle:

Principle #25Self-service

2Productivity

If manual measurement is used, then device complexity remains low, but productivity and time efficiency deteriorate

Engineering Contradiction:

ImproveproductivityVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces time-consuming manual measurement processes with an automated optical measurement system. The rangefinder can rapidly capture multiple dimensional parameters simultaneously, significantly increasing measurement speed and productivity while reducing the time each product spends in the quality control process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The measurement system is designed to continuously measure products as they move through the production line. The automated system can maintain continuous operation without the interruptions associated with manual measurement, ensuring uninterrupted productivity flow while consistently capturing dimensional data for quality control.

Inventive Principle:

Principle #20Continuity of useful action

3Measurement precision

If automated measurement system is introduced, then measurement precision and productivity improve, but manufacturing cost increases

Engineering Contradiction:

Improvemeasurement precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent employs an optical rangefinder system that, while automated, uses non-contact measurement technology to avoid the need for complex mechanical measurement apparatus. This approach reduces manufacturing costs compared to traditional automated mechanical systems while maintaining high measurement precision and consistency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Loss of time

If manual measurement is used, then initial cost remains low, but loss of time and operational efficiency deteriorate

Engineering Contradiction:

Improveloss of timeVSAvoiddevice complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The patent replaces manual measurement operations with an automated optical system that instantly captures dimensional data. This substitution eliminates the time workers spend on manual measuring, marking, and recording, while the relatively simple optical device requires minimal maintenance and operation training.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Enables rapid, precise, and cost-effective automatic measurement of geometric and structural parameters, reducing variability and ensuring compliance with design specifications, while being easily implemented and safe to use.

Implementation Method 1

said frame also supporting at least one rangefinder which is aligned with at least one face of said mattress, pillow and the like

Methodology Applied

Scientific EffectLight reflection and time of flight measurement: Time of Flight

Data Source

PatentUS10271662B2Station for detecting, controlling, checking and comparing physical parameters of a mattress, a pillow and the like

Publication Date: 2019.04.30 RESTA SRL

AI summary

A station for detecting, controlling, checking, and comparing physical parameters of a mattress or a pillow, includes a retention frame for a resting surface, designed to support the mattress or the pillow. The resting surface, at one of its corners, includes respective abutment walls for concurrent side faces of the mattress or the pillow. The frame also supports at least one rangefinder which is aligned with at least one face of the mattress or the pillow that lies opposite the respective faces that rest on the resting surface and against the walls.