AUTOMATED MATTRESS MANUFACTURING PROCESS AND APPARATUS

摘要

An automated system and process for manufacturing a mattress generally includes an automated foam layer placement apparatus for accurately securing one or more foam layers onto an innercore unit and bucket assembly.

主权项

1. An automated system for fabricating a mattress, the system comprising:
a plurality of stations comprising:
an automated coil unit assembly station comprising a coiler in operative communication with a coil staging apparatus to form a continuous string of pocketed coils;an automated innercore assembly station in operative communication with the coil staging apparatus configured to receive and cut the continuous string of pocketed coils to form string segments of the pocketed coils, and assemble and adhesively attach rows of the string segments to define a pocketed spring innercore;an automated bucket assembly station in operative communication with the automated innercore assembly to receive the pocketed spring innercore, wherein the automated bucket assembly station is configured to form a foam bucket defined by a foam base layer and foam side rails about a perimeter thereof to form a cavity, wherein the innercore is inserted into the foam bucket to form an innercore unit and bucket assembly; andan automated foam pick layer pick and place assembly station for placing and securing one or more foam layers onto the innercore unit and bucket assembly; a common conveyor for serially conveying an output from the automated coil unit assembly station to the automated innercore assembly station to the automated bucket assembly station and to the automated foam pick layer pick and place assembly station to form the innercore and bucket assembly including one or more foam layers disposed thereon; and a manufacturing execution system and programmable logic control for planning, scheduling, and controlling the plurality of stations.