U.S. patent number 3,774,652 [Application Number 05/219,765] was granted by the patent office on 1973-11-27 for spring transfer apparatus.
This patent grant is currently assigned to Frank L. Wells Company. Invention is credited to Helmuth Sturm.
United States Patent |
3,774,652 |
Sturm |
November 27, 1973 |
SPRING TRANSFER APPARATUS
Abstract
Conventional coil springs having a knot on both top and bottom
convolutions are delivered to a rotating transfer drum of hexagonal
shape having magnetized flat surfaces around which pass a pair of
endless belts and which thus have movement with the transfer drum.
The top run of each belt passes over and is supported by the
magnetized top surface of a longitudinal table. The coil springs
which are delivered to the transfer drum one at a time adhere to a
flat surface thereof and are caused to move with the endless belts
along the top surface of the table to form a longitudinal row.
Solenoid actuated positioning pins provided along the length of the
table are actuated in succession to stop a coil spring and hold the
same in stopped position while the belts continue to move. Lower
pusher arms are actuated to simultaneously push all the coils of a
positioned row off the belts and onto turntables respectively which
are in a lowered position for receiving the same. The turntables
are thereupon elevated and rotated to rotate each coil in a
selective direction to obtain the desired knot orientation in the
completed mattress or other inner spring structure. A plurality of
upper pusher arms are next actuated to push all the coils from off
the elevated turntables and onto the dies of an assembling unit and
which dies are open at the time for receiving the top and bottom
convolutions of the coils respectively.
Inventors: |
Sturm; Helmuth (Kenosha,
WI) |
Assignee: |
Frank L. Wells Company
(Kenasha, WI)
|
Family
ID: |
22820684 |
Appl.
No.: |
05/219,765 |
Filed: |
January 21, 1972 |
Current U.S.
Class: |
140/3CA |
Current CPC
Class: |
B21F
33/04 (20130101); B21F 27/16 (20130101) |
Current International
Class: |
B21F
27/00 (20060101); B21F 33/04 (20060101); B21F
33/00 (20060101); B21F 27/16 (20060101); B21f
027/16 () |
Field of
Search: |
;140/3CA,92.3,92.7,92.8
;198/41 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Larson; Lowell A.
Claims
What is claimed is:
1. In a method of transferring resilient coil springs, each having
a knot on their top and bottom convolutions, from a coiler where
the coils are produced to an assembling unit where the coils are
joined to form an interior spring structure, the steps which
include receiving the coil springs one at a time as they are
produced by the coiler and positioning a pre-determined number of
the coil springs in spaced relation in a first longitudinally
aligned row, simultaneously pushing all the coils of said row onto
turntables respectively, elevating and rotating the coils of said
row by elevating and rotating each turntable, whereby the coils of
said row are now at a higher elevation with the coils having been
turned for the desired knot orientation, and finally pushing the
coils of said row from off the elevated turntables and onto the
respective top and bottom dies of the assembling unit which dies
are open at the time for receiving the top and bottom convolutions
thereof.
2. In a method of transferring resilient coil springs as defined by
claim 1, wherein the step of positioning a pre-determined number of
coil springs in spaced relation in a first longitudinal row takes
place in succession for the second and all subsequent rows, and
wherein the step of rotating the coils by rotating each turntable
takes place selectively with some turntables and their coils
rotating clockwise and the others rotating counter-clockwise.
3. In a method of transferring resilient coil springs as defined by
claim 1, wherein the step of pushing the coils of said row from off
the turntables and onto the dies of the assembling unit includes
the steps of positively gripping each coil as the same is pushed
off the turntable and maintaining the grip on each coil until the
coil is located on the said dies, and finally the step of releasing
the grip thus leaving the coil located on the dies in the desired
position.
4. In a method of transferring resilient coil springs as defined by
claim 1, wherein the step of positioning a pre-determined number of
coil springs in spaced relation in a first longitudinal row
includes the step of moving the coils along a horizontal
longitudinally extending table by means of intermittently moving
belts, the top run of which pass over and are supported by the said
longitudinal table, and the steps of stopping movement of the coils
seriatim in desired spaced relation while the belts continue to
move, and in holding each coil in its respective stopped position
until the entire row is pushed off the belts and onto the
turntables.
5. In a method of transferring resilient coil springs as defined by
claim 4, wherein the step of moving the coils along said horizontal
longitudinally extending table by means of the continously moving
belts and the step of holding each coil in its respective stopped
position are materially assisted by subjecting the coils to
magnetic attraction effected by magnets comprising part of the
longitudinally extending table.
6. In a method of transferring resilient coil springs, each having
a knot on their top and bottom convolutions, from a supply of said
coils to an assembling unit where the coil springs are joined to
form an interior spring structure, said assembling unit including
top and bottom forward dies and top and bottom rear dies, the steps
which include receiving the coil springs one at a time and
positioning a pre-determined number of the coils in spaced relation
in a first longitudinally aligned row and with their axes disposed
vertically, simultaneously pushing all the coils of said row onto
turntables, respectively, elevating and rotating the coils of said
row by elevating and rotating each turntable, whereby the coils of
said row are now at a higher elevation with the coils having been
turned selectively for the desired knot orientation, repeating the
above operations for the second and each subsequent row as required
for the particular spring structure, pushing the coils of said
first row from off the elevated turntables and onto the respective
top and bottom forward dies of the assembling unit which dies are
open at the time for receiving the top and bottom convolutions
thereof, and thereafter pushing the coils of the second and
subsequent rows in succession from off the turntables and onto the
respective top and bottom rear dies of the assembling unit which
are open at the time for receiving the top and bottom convolutions
thereof.
7. In a method of transferring resilient coil springs as defined in
claim 6, wherein the step of rotating the coils by rotating each
turntable takes place as the coils are being elevated, and wherein
the rotation is selective with some turntables and their coils
rotating clockwise and the others rotating counterclockwise.
8. In a method of transferring resilient coil springs as defined by
claim 6, wherein the step of positioning a pre-determined number of
coil springs in spaced relation in said first and subsequent
longitudinal rows includes the step of moving the coils along a
horizontal longitudinally extending table by means of moving belts
having their top runs passing over and being supported by the
longitudinal table, and also the steps of stopping the movement of
the coils seriatim in desired spaced relation while the belts
continue to move, and in holding each coil in its respective
stopped position until the entire row is pushed off the belts and
onto the turntables.
9. In a method of transferring resilient coil springs as defined by
claim 6, wherein the step of pushing the coils of each said row
from off the turntables and onto the dies of the assembling unit
includes the step of positively gripping each coil as the same is
pushed off the turntable and maintaining the grip on each coil
until the coil is located on the said dies, and finally the step of
releasing the grip thus leaving the coil located on the dies in the
desired position.
10. In apparatus for handling and transferring conventional knotted
coil springs, the combination with a supply of the coil springs, of
endless belt structure located relatively near the supply and
including a transfer drum at the supply end and a second drum at
the opposite end of the structure, endless belts passing around the
said drums and providing longitudinally extending top and bottom
runs therebetween, a longitudinal table also extending between the
drums and having the top run of the endless belts passing over and
being supported by the table, said transfer drum having a plurality
of flat surfaces which directly support the belts as they pass
around the transfer drum, magnetic means in operative associated
relation with each flat surface of the transfer drum, and means for
rotating the transfer drum during operation of the apparatus to
cause movement of the endless belts, whereby a coil spring from the
supply upon being presented to a certain flat surface will adhere
thereto with a portion of the endless belts being interposed
between the flat surface and the bottom convolution of the coil
spring.
11. In apparatus for handling and transferring conventional knotted
coil springs as defined by claim 10, additionally including
magnetic members extending longitudinally and forming a top surface
for the table and which thus have the top run of the belts passing
over and being supported thereby.
12. In apparatus for handling and transferring conventional knotted
coil springs as defined by claim 11, wherein the top surface of the
table includes a pair of said longitudinal magnetic members in
spaced relation, and additionally includes a metal center plate
located between the magnetic members to complete the top surface,
and wherein a pair of endless belts are employed with each belt
having its top run passing over and being supported by a magnetic
member, whereby a coil spring in magnetically adhered relation with
a certain flat surface may be moved bodily from an axial horizontal
position to an axial vertical position by rotation of the transfer
drum, and whereby a plurality of vertically positioned coil springs
may be moved by the moving belts along the table to form a
longitudinally aligned row with the coils being magnetically
attracted and held on the belts by the magnetic members.
13. In apparatus for handling and transferring conventional coil
springs as defined by claim 11, wherein the magnetic means in
associated relation with each flat surface of the transfer drum and
the longitudinal magnetic members which form the top surface of the
table both comprise magnets of the permanent type.
14. In apparatus for transferring coil springs from a coiler to an
assembling unit, in combination, endless belt structure for
receiving the coil springs from the coiler and for moving and
positioning the coils in a longitudinal row, said endless belt
structure including a longitudinally extending table providing a
flat top surface, a rotatable transfer drum at the coiler end of
the table, a second drum rotably mounted at the opposite end of the
table, a pair of endless belts passing around the drums at
respective ends and having their top runs passing over and being
supported by the table, said belts being transversely spaced and a
center plate forming part of the top surface of the table having
location between the belts, a plurality of positioning pins
disposed in spaced relation along the length of the table, means
supporting the positioning pins for vertical movement including
solenoids respectively, said pins normally having an inoperative
position below the center plate and an operative position
projecting above the plate upon energization of their particular
solenoid, means intermittently rotating the transfer drum during
operation of the apparatus to cause intermittent movement of the
endless belts, and electrical means for energizing the solenoids
one at a time and in succession in a direction reverse to the
movement of the belts, whereby said pins upon being rendered
operative are located in the path of a coil spring to stop movement
of the same and hold the coil in position while the belts continue
to move.
15. In apparatus for transferring coil springs from a coiler to an
assembling unit as defined by claim 14, additionally including a
pair of longitudinal magnetic members of the permanent magnetic
type supported by the table on respective sides of the center plate
and forming with said plate the top surface of the table, wherein
the top run of each belt passes over and is supported by a magnetic
member, wherein each solenoid supports a pair of transversely
spaced positioning pins and which are vertically movable from an
inoperative position below the center plate to an operative
position projecting above the plate upon energization of their
particular solenoid, and additionally including a pair of fixed
positioning pins provided by the table in a stationary position
projecting above the center plate, said fixed pair of positioning
pins being located in longitudinal alignment with the solenoid
actuated pins and at the operative end of the longitudinal table
relatively adjacent the second rotatably mounted drum.
16. In apparatus for transferring knotted coil springs from a
supply of said coils to an assembling unit where the coils are
joined to form an inner spring structure, in combination, endless
belt structure including a longitudinal table having a flat top
surface, a rotating transfer drum at the supply end of the table, a
pair of endless belts adapted to have movement and which pass
around the transfer drum at one end and have their top runs passing
over and being supported by the top surface of the table, whereby
coil springs delivered one at a time to the transfer drum are
transfered thereby to the belts and which effect movement of the
coils in succession along the top surface of the table, a plurality
of positioning pins provided by the table in spaced relation
longitudinally thereof, a plurality of solenoids for supporting the
pins respectively for vertical movement from a normal inoperative
position below the said top surface to an operative position above
the top surface upon energization of their particular solenoid,
said pins upon being rendered operative projecting above the belts
and into the path of a coil spring being moved by the belts,
whereby to stop movement of the coil and produce a longitudinal row
in stopped position on the belts while the belts continue to move,
a plurality of turntables each being supported for vertical
movement and for rotation in a predetermined direction, each
turntable being located in associated relation with the endless
belts and in aligned relation with one of said solenoids,
reciprocable pusher arms equal in number to the number of
turntables, each pusher arm having an aligned relation with a
positioned coil spring and with its respective turntable, and means
for actuating the pusher arms in an operative direction to
simultaneously push the entire row of positioned coil springs off
the belts and onto the turntables respectively.
17. In apparatus for transferring knotted coil springs as defined
by claim 16, additionally including a pair of spaced permanent
magnetic members forming the top surface of the table and having a
metal center plate located therebetween, wherein the top run of an
endless belt passes over and is supported by a magnetic member,
wherein a pair of transversely spaced positioning pins are
supported and actuated by each solenoid, and additionally including
a pair of fixed positioning pins provided by the table in a
stationary position projecting above the center plate, said fixed
pair of positioning pins being located in longitudinal alignment
with the solenoid actuated positioning pins and at the other end of
the table from the transfer drum.
18. In apparatus for transferring knotted coil springs from a
supply of said coils to an assembling unit where the coils are
assembled to form an inner spring structure, in combination with,
endless belt structure including endless belts and which are
adapted to have movement for receiving the coils from the said
supply and for moving the coils along the endless belt structure in
a longitudinal row, a plurality of solenoid actuated positioning
pins in associated relation with the endless belt structure for
stopping movement of the coil springs in succession and for holding
each coil in stopped position on the belts while the belts continue
to move, a plurality of vertically movable turntables in associated
relation with the solenoid actuated positioning pins respectively,
lower pusher arms having reciprocating movement for simultaneously
pushing all the coils in stopped position from off the belts and
onto the turntables, gear means having operative connection with
each turntable for selectively rotating the same in either a
clockwise or a counter-clockwise direction, whereby the coil
springs supported by the turntables can be rotated individually for
achieving a desired knot orientation, and upper pusher arms also
having reciprocating movement for pushing the coil springs from off
the turntables and onto dies respectively, said dies forming part
of the assembling unit and which are open at the time for receiving
the top and bottom convolutions of their particular coil
spring.
19. In apparatus for transferring knotted coil springs as defined
by claim 18, additionally including a pair of magnetic members of
the permanent magnetic type forming part of said endless belt
structure and wherein a pair of endless belts are employed with
each belt having its top run passing over and being supported by a
magnetic member, wherein the solenoid actuated positioning pins
comprise a plurality of pairs of pins with each pair being
supported and actuated by a solenoid, and additionally including
power means for reciprocating the lower pusher arms, independent
power means for moving all the turntables and their gear means
vertically as a unit, whereby the turntables and their associated
gear means may be bodily elevated as a unit above the endless belt
structure and whereby the turntables may be rotated during the
elevating operation, and other independent power means for
reciprocating the upper pusher arms.
20. In apparatus for transferring knotted coil springs as defined
by claim 19, wherein the turntables are each provided with magnetic
members of the permanent magnetic type whereby to assist in holding
the coil springs on the turntables as the same are being elevated
and rotated.
21. In apparatus for transferring knotted coil springs as defined
by claim 18, additionally including a pair of opposed coil gripping
fingers pivotally carried by each upper pusher arm at the forward
end of the same, resilient means in association with each pair of
fingers for resiliently maintaining the same in a closed coil
gripping position, reciprocable cam means also carried by each
pusher arm for opening the gripping fingers against the tension of
said resilient means when reciprocated in a forward direction,
power means for reciprocating the upper pusher arms, and other
independent power means carried by the upper pusher arm structure
and movable therewith for simultaneously actuating all the cam
means to cause forward and rearward reciprocating movement thereof.
Description
The invention relates to a method and to a machine for
transferring, positioning and assembling coil springs in the
production of mattresses and the like and has reference in
particular to improvements in apparatus for receiving hour-glass
shaped coil springs from a coiler and which in the process of
transferring the coil springs from the coiler to a mattress
assembling unit will rotate individual springs selectively for knot
orientation.
In spring assembling machines for making inner spring units for
mattresses, box springs and the like, the conventional procedure
required the services of an operator for placing the coil springs
manually into separate pockets of the spring assembling machine and
which were thereupon propelled forwardly and connected at
respective end convolutions by helical springs. In the machine of
the present invention the coil springs are received from the coiler
one at a time as they are produced and all subsequent operations
from the coiler to the spring assembling unit are automatic
including the new and novel step of positioning a plurality of said
coil springs in a longitudinal row and in rotating the coil springs
of each positioned row in either a clockwise or a counter-clockwise
direction for knot orientation, both steps being performed during
the process of transferring the coil springs from the coiler and
before they are propelled forwardly into the assembling unit. For
accomplishing the foregoing operations the present machine
incorporates endless belts wherein the upper runs thereof pass over
longitudinal magnets, wherein solenoid actuated pins are provided
for positioning the coils in a longitudinal row while the belts
continue to have movement and wherein turntables receive the coil
springs from the belts and elevate them in addition to turning the
coils approximately 90.degree. in selected directions to orient the
knots on the end convolutions.
In view of the foregoing, a main objective of the present invention
resides in the provision of endless belts for receiving the coil
springs from the coiler or from a supply of said coils and for
positioning the coils in longitudinal alignment and wherein the
coils are properly spaced and held in position in spaced relation
by means of solenoid actuated pins. The upper runs of the belts
pass over longitudinal magnets respectively, which assist in
holding the coil springs on the belts while the belts have movement
for transferring and locating the coil springs that follow in their
aligned spaced positions.
Another object resides in the provision of apparatus as described
which will additionally incorporate horizontally reciprocating
pusher arms for pushing the longitudinally aligned row of
uniformily spaced coil springs forwardly off the belts and onto
turntables respectively, the said turntables each having a lowered
position for receiving the coil springs from the belts and
thereafter having an elevated position.
Another object of the invention is to provide a plurality of
turntables for individually receiving the coil springs from the
belts, the said turntables having a lowered position for such
purpose and wherein the turntables are immediately thereafter
elevated to locate the entire row of aligned coil springs at an
elevation above and forwardly of the continuously moving belts. In
the process of elevating the coil springs, the turntables are
rotated in either a clockwise or a counter-clockwise direction for
knot orientation.
Another object resides in the provision of a second set of pusher
arms having horizontal reciprocation for pushing the rotated coil
springs from off the turntables and onto dies which at the time are
open for receiving the top and bottom convolutions respectively. As
the pusher arms are reciprocated forwardly, the coil gripping
elements of each arm are caused to open momentarily against spring
tension and to then close in gripping relation with a coil spring,
whereby adequate control is obtained at all times in pushing the
coil springs off the turntables respectively and into the open dies
as regards their end convolutions.
With these and other objects in view, the invention may consist of
certain novel features of construction and operation as will be
more fully described and pointed out in the specification, drawings
and claims appended thereto.
In the drawings which illustrate an embodiment of the invention and
wherein like reference characters are used to designate like
parts;
FIG. 1 is a top olan view showing spring transfer apparatus
embodying the improvements of the invention including the endless
belts, the upper run of which pass over longitudinal magnets, the
lower pusher arms, the turntables and the upper pusher arms;
FIG. 2 is an elevational view of the operator's side of the spring
transfer apparatus as shown in FIG. 1;
FIG. 3 is part elevational and part sectional view taken
substantially on line 3--3 of FIG. 4 and showing the endless belt
structure in combination with the solenoid actuated positioning
pins;
FIG. 4 is a vertical sectional view taken transversely through the
spring transfer apparatus of the invention and showing details of
the various improved features;
FIG. 5 is a transverse sectional view showing details of the
endless belts with their upper run being supported on
longitudinally extending magnets and also showing a pair of the
solenoid actuated positioning pins in up position;
FIG. 6 is a fragmentary detail sectional view similar to FIG. 5 and
illustrating one pair of positioning pins in down position;
FIG. 7 is a transverse sectional view taken vertically and showing
details of the elevating and rotating structure for the turntables,
the adjustable geat wheel having an up position;
FIG. 8 is a fragmentary detail sectional view of the turntable
structure showing a down position of the adjustable gear wheel;
FIG. 9 is a fragmentary sectional view illustrating an operation of
an upper pusher arm in pushing a coil spring of the gear row from
off of a turntable and onto forward dies which are open for
receiving the top and bottom convolutions respectively;
FIG. 10 is a fragmentary sectional view similar to FIG. 9 but
illustrating an operation of the upper pusher arm in pushing a coil
spring from the second and subsequent rows onto the rear dies which
are open for receiving the convolutions respectively;
FIG. 11 is a fragmentary sectional view similar to FIGS. 9 and 10
and showing the dies in closed position on the convolutions of a
pair of coil springs from transversely adjacent rows and wherein
the convolutions overlap;
FIG. 12 is an enlarged fragmentary sectional view illustrating the
action of a helical coil in joining the overlapping portions of the
convolutions of the coil springs;
FIG. 13 is a top plan view showing portions of a coil spring
mattress such as can be produced by the spring transfer apparatus
of the invention;
FIG. 14 is a fragmentary plan view showing a group of coil springs
as illustrated in the mattress of FIG. 13 in connected relation by
means of a helical coil which joins adjacent convolutions of the
springs;
FIG. 15 is a top plan view showing details of the upper pusher
arms;
FIG. 16 is a side view of the pusher arm shown in FIG. 15; and
FIG. 17 is a top plan view similar to FIG. 15 but showing the coil
gripping elements of the pusher arm in an actuated open
position.
Referring to the drawings and in particular to FIG. 13 it will be
understood that the coil spring transfer apparatus of the invention
is capable of producing spring interiors such as mattresses,
cushions and etc. and wherein the same are formed of resilient wire
coil srings generally of a helical hour glass shape and wherein the
ends of the wire are connected to the top and bottom convolutions
by knots. In FIGS. 13 and 14 the coil springs are designated by the
numeral 10, the knots by the numeral 11 and the helical coils which
join the top and bottom convolutions of transversely adjacent rows
by the numeral 12. In FIG. 13 the top convolutions of rows 1 and 2
are joined by a helical coil 12, and likewise a helical coil joins
the top convolutions of rows 2 and 3 and so on. The bottom
convolutions of said coil springs are joined in the same manner.
Also the coil springs have been selectively rotated to orient the
knots 11 as shown so that the forward edge of the mattress and also
the two side edges and the rear edge will be free of knots since
the coils have been so rotated as to position the knots inwardly of
the mattress structure.
THE ENDLESS BELT STRUCTURE
The coil springs 10 are produced by a coiler, FIG. 1, well known in
the art and which need only be designated by the block diagram 14.
The coils are pushed forwardly of the coiler so as to be positioned
in contact with a flat magnetized surface 15 of the transfer drum
16, FIG. 2, The drum is rotated intermittently by the drive
sprockets 17 and 18 connected by the endless chain 20, the drive
preferably having operative connection with the coiler 14 so that
the drive to the belts synchronizes with the operation of the
coiler. The upright standards 21 support journalling means 22 for
the drum 16 and the standards are in turn supported by the frame
structure 23, the same including the vertical right hand frame
standards 24. Each flat surface 15 of the hexagonal drum 16 is
rendered magnetic by the permanent magnets 25 shown in FIG. 3 and
thus the coil springs are held to a flat surface and elevated to a
horizontal position as the drum 16 rotates.
A pair of endless belts 26 pass around the drum 16 at the right
hand end of the belt structure, FIGS. 2 and 3, and the belts pass
around the circular drum 27 at the left hand end of the same. The
circular drum is journalled at 28 and the drum is supported by the
element 29 from the left hand frame standard 30. A pair of spaced
endless belts 26 are employed as shown in FIG. 5 and said belts
have their upper runs passing over and the same are thus supported
respectively by a pair of longitudinally extending magnets 31. Said
magnets are of the permanent type and they extend from drum 16 to
drum 27. A longitudinally extending channel member 32 is supported
by frame element 33 from the standards 24 and 30 and said member 32
supports the magnets 31 which are insulated at 34. The member 32
also supports the center metal strip or plate 35 by suitable blocks
not shown. The insulating tubes 36 are anchored in channel 32 and
they extend upright to pass through the plate 35. Said plate
extends between the belts 26 forming a separator so as to maintain
the belts in contact with their magnet 31 and which function is
assisted by the side guides 37. The belts, magnets and plate
provide a horizontal supporting table for the coils which adhere to
the belts due to the magnets. With continuous movement of the belts
in an intermittent manner, the coil springs are first received by
the transfer drum one at a time and as the drum rotates the coils
are positioned upright and delivered to the longitudinal table.
While on the table the coils are moved by the belts to form a row
of longitudinally aligned and spaced coils.
THE SOLENOID ACTUATED POSITIONING PINS
Although the endless belts continue to move, the coils are stopped
and held against movement by pairs of positioning pins 40, shown in
FIGS. 5 and 6,and which are employed for positioning each coil
spring and the pins extend through the tubes 36 so it will be
understood that the pins are insulated from the channel member 32
and also from the metal center strip 35. The pins are further
insulated from the frame of the machine since they are suitably
anchored in the insulation block 41, and have their lower extending
ends connected to the conductor leads 42. As best shown in FIG. 3,
a plurality of pairs of pins are positioned in longitudinal
alignment between the frame standards 24 and 30 and each pair, with
the exception of the first pair, is actuated from a down position
to an up position by electro-magnetic means such as a solenoid 43.
For illustrative purposes it can be assumed that the present
apparatus embodies a total of 15 pairs of pins and 14 solenoids
with pair 1 being located on the extreme left, FIG. 3, then pair
2,3,4,etc. until the last pair 15 is located on the extreme right.
The pins of the first pair are fixed in an up position so that the
first coil will contact the pins as shown and remain in held
position while the belts continue to move. The second pair of pins
are actuated by the solenoid 43 of said pair, the solenoid having a
stem 44 which is suitably fixed to its insulating block 41. The
remaining solenoids are connected to their pins in a similar manner
and the solenoids and pins are disposed in spaced relation for
spacing the coil springs in a longitudinal row as required for the
particular inner spring structure to be produced.
In starting operation of the present machine, the first coil will
be received from the coiler and transferred by the moving belts to
the first pair of positioning pins. The pins of said first pair are
up at all times and so the first coil will contact the same and be
held thereby. This contact of the metal coil with the positioning
pins will close an electric circuit so as to energize the solenoid
for the pins of pair 2 and said pins will move up as shown in FIG.
5 to stop and position coil 2. When coil 2 contacts its pins it
energizes the solenoid for coil 3 and so on until all coils have
been positioned on the belts in longitudinal alignment. The
conductors 42 form the positive of the electric circuit for each
solenoid with the metal of the frame providing a grounded negative.
More particularly each coil spring will have its base convolution
in contact with a pair of positioning pins 40 with its top
convolution in contact with the metal slide plate 45, FIG. 5. Thus
the coil will function in a manner to close an electrical circuit
such as will energize the next solenoid on its right side, FIG. 3.
Since the belts continue to move intermittently, they help to
maintain the coils against their pair of pins and said movement has
the desirable effect of stabilizing the coil positioning
operation.
THE LOWER PUSHER ARMS
The lower pusher arms 46 are actuated at intervals in timed
relation with the positioning of the last or number 15 coil so as
to push all 15 of the positioned coil springs off the moving belts
26 and onto turntables 47 disposed in down position for receiving
the coil springs, see FIGS. 1,2 and 7. A pusher arm is required for
each coil and the arms are fixed to a reciprocating channel member
48 with each arm at its opposite end carrying a coil engaging
element 49. The numeral 50 indicates a slide supporting bar for the
channel member 48 and which is thus supported for horizontal
reciprocating movement. Said movement is imparted to the lower
pusher arms 46 at predetermined times by the power cylinders 51,
FIGS. 2 and 4, suitably supported on the frame standards 24 and 30
respectively at each end of the member 48. The power cylinders each
have a piston actuated rack 52 in meshing relation with a gear
wheel 53. The gear wheel thus rotates to oscillate the arms 54
which reciprocate the sliding element 55 on the slide bar 50. The
channel member 48 is fixed at respective ends to the elements
55.
Immediately following the positioning of the last coil in the
aligned row on the moving belts, the power cylinders 51 are
rendered operative to move the pusher arms 46 in a forward
direction, whereby all coils of the row are simultaneously pushed
forwardly off the belts and onto the turntables 47. The pusher arms
return immediately since the belts continue to move and another
coil spring number 1 etc. as regards a new row is being moved by
the belts and the pusher arms 46 must be retracted out of the
way.
THE TURNTABLES
The turntables rotate as they are elevated from a low position in
horizontal alignment with the moving belts to an elevated position
in substantial horizontal alignment with the bottom or lower dies
to be presently described, FIGS. 7,9 and 10. A turntable for each
coil is provided and the mechanism for supporting and for rotating
the turntables forms a unit and the units are all supported for
elevating movement which is effected by the power cylinders 58 best
shown in FIG. 4. The longitudinally extending metal supporting beam
59 is elevated upon actuation of the power cylinders and
accordingly said beam at its respective ends is mounted for
vertical movement on the slide bars 60. For such purpose each end
of the beam is provided with a sliding member 61 secured to the
beam and stabilized by member 62. The vertical flange of the beam
is connected at 63 with the piston rods of the power cylinders 58
and the horizontal flange provides the support for the cylinders
64, FIG. 7, one for each turntable. Each cylinder 64 journals a
tube 65 for rotation on a vertical axis for which purpose the ball
bearing element 66 is provided. The tube at its top end is fixed to
a turntable 47 as by means of the stem 67 and the fastening screw
68. Since the turntables must have either clockwise or
counter-clockwise rotation, the invention provides an adjustable
gear 70 which is fixed to the tube 65 by the set screw 71 in either
an up position, FIG. 7, or in a down position FIG. 8. The gear has
meshing relation when in up position with a longitudinally
extending rack 72 located on the right hand side of the gear 70 and
fixed to the actuating member 73 supported by the element 74. When
the gear is fixed in down position, FIG. 8, the gear has meshing
relation with the rack 75 secured to the actusting member 76 which
is supported by the support 77.
The turntables 47 are each provided with a number of permanent
magnets 78 located around the periphery of the turntable and which
assist in holding the coil spring on the turntable. Whereas the
bottom convolution is held on the turntable by magnetic attraction,
the top convolution is in contact with the top slide plate 80,
which is unitary with the turntable structure and moves up and down
with the turntables upon actuation of the power cylinders 58. As
the turntables are elevated from their low or down position, the
racks 72 and 75 are simultaneously reciprocated by the power
cylinders 81 shown in FIG. 2, to in turn rotate the turntables and
thus the coils supported thereby for knot orientation. For certain
turntables the gear 70 will be in meshing relation with the rack 72
for rotating the turntables in a counterclockwise direction and for
other turntables the gear 70 will be in meshing relation with rack
75 for rotating the turntables in a clockwise direction. The final
result of the operation is to orient the knots on the various coil
springs as shown in the mattress of FIG. 13.
THE UPPER PUSHER ARMS
Following the elevation and rotation of the coil springs
individually supported on a turntable, the upper pusher arms 82 are
next actuated for pushing the coil springs from off the turntables
and into dies which at the time are open for receiving the top and
bottom convolutions thereof. The combination angle and channel
member 83 extends longitudinally of the machine from frame standard
24 to frame standard 30 and the upper pusher arms 82, one for each
turntable, are fixedly secured thereto. The member 83 is supported
for reciprocating movement by the sliding members 84 which have
sliding movement on the rods 85, located at each end of the member
83. A power cylinder 86 is suitably supported on each frame
standard 24 and 30 and each cylinder has a piston connected rack 87
in mesh with a gear wheel 88. Oscillation of the gear wheel will
oscillate the arms 90 and thus the member 83 and the upper pusher
arms 82 are reciprocated.
As shown in FIGS. 15,16 and 17 the upper pusher arms 82 are
provided at their forward ends with coil gripping elements 91,
which are pivotally carried by each arm and spring tensioned by the
resilient springs 92 to close on and grip a coil spring 10. Said
springs 92 are carried by the connecting pin 93 and each resilient
spring is located outside a coil gripping element and held on the
pin by the retaining nut 94.
Each pusher arm is slotted at 95 to receive the pin 96 which is
carried by a connecting member 97 extending longitudinally from the
first pusher arm to the fifteenth or last pusher arm. The pin 96 of
each pusher arm is in turn fixed to a cam bar 98 carried by each
pusher arm and having a cam shaped forward end 100 for effecting an
opening action of the coil gripping elements 91. The power
cylinders 101 shown in FIG. 1 are suitably carried by reciprocating
channel member 83 and the piston end of each cylinder is connected
at 102 to the connecting member 97 and through the pins 96 to the
cam bars 98. As the upper pusher arms 82 are moved forwardly to
push the row of coil springs from off the turntables and into dies,
such as 103 to 106 inclusive shown in FIGS. 9 and 10, the power
cylinders 101 are energized and the cam bars are moved forwardly to
cause the coil gripping elements to open. Thus it will be seen that
when the pusher arms 82 are moved forwardly, the coil gripping
elements 91 are immediately caused to open so that said elements
may receive a coil spring and resiliently grip the same upon
retraction of the cam bars 98 which action thereupon takes place
following contact of the gripping elements with a coil spring.
THE DIES AND THE HELICAL COIL CONNECTING OPERATION
As previously explained, when the coil springs have been elevated
and rotated by the turntables, they are pushed by the upper pusher
arms 82 from off the turntables and into the dies 103 to 106
inclusive which are at the time open for receiving their respective
top and bottom convolutions. This action of the upper pusher arms
is illustrated in FIGS. 9 and 10. The top dies 103 and 104 are
suitably supported by frame structure 107 and each die has a
special formation including a semi-circular recess such as 108 and
109 respectively. The lower dies 105 and 106 are likewise supported
by frame structure 110 and said dies have semicircular recesses 111
and 112.
For the first row of coil springs as designated in FIG. 13, the
pusher arms 82 will have their maximum reciprocating movement
forwardly so as to push the entire first row off the turntables and
into the forward dies 103 and 105 as regards their top and bottom
convolutions. The top convolution will encircle the top forward die
103 and the semi-circular recess 108 will receive part of the same.
In a like manner the bottom convolution will encircle the lower
forward die 105 and the semi-circular recess 111 will receive part
of the same. The pusher arms 82 are permitted to reciprocate their
full extent for this first row since the power cylinder 114 FIG. 4,
will have been energized to withdraw the block 115 carrying the
stop member 116. As a result the rack 87 will move up to its full
extent until it contacts the stop 117. On subsequent operations for
the second,third and the remaining rows the block 115 will have
been moved forwardly and located again in its former position and
thus the rack will next engage the stop 116 which action will
reduce the length of the forward reciprocating stroke of the pusher
arms 82. On these subsequent operations of the upper pusher arms
for the second, third and remaining rows, the coil springs from the
turntables will be pushed into the rear dies 104 and 106, see FIG.
10. The top convolution will encircle the top rear die 104 and part
will lie in the recess 109. The bottom convolution will encircle
the lower rear die 106 with part lying in the recess 112. With the
completion of each forward feeding operation as above described for
the subsequent rows, the dies are caused to close and the
convolutions in the respective semicircular recesses will overlap
as shown in FIG. 11. Each circular opening thus formed by the
closed dies will receive a helical coil 12 which joins the
overlapping convolutions of adjacent rows of coils as illustrated
in in FIGS. 12 and 13.
The helical coil 12 is formed by the machine 118 FIG. 1 and the
helical is fed transversely of the mattress structure to join the
convolutions of adjacent rows of coil springs. Means are provided
for cutting the helical coil when it has been fed for the required
length and each end of the helical coil wire is then bent inwardly
to complete the connecting operation on adjacent transverse rows of
coil springs.
OPERATION OF THE MACHINE
As the coil springs are produced by the coiler 14 they are pushed
forwardly onto a magnetized flat surface 15 of the transfer drum
16. By the rotation of the drum the coils are bodily moved from a
horizontal axial position to a vertical position and since the
endless belts 26 pass over the transfer drum, the coils are moved
by the belts along the longitudinal table formed by the spaced
magnets 31 and the center metal plate 35. The magnets assist in
holding the coil springs on the belts while the coils move with the
belts and until they contact the coil positioning pins 40 which are
solenoid actuated as described. Thus the coils are properly spaced
and maintained in position longitudinally to form a row. When the
row is complete as regards the number of coils, the lower pusher
arms are actuated by the power cylinders 51 to push the entire row
onto the turntables 47 which at the time will be in down position
for receiving the coil springs. The turntables rotate each coil
spring as they are being elevated to a position above and forwardly
of the endless belts. At predetermined times in synchronism with
the operations of the turntables, the upper pusher arms 82 are
reciprocated forwardly to push the coils from off the turntables
and onto the dies 103 to 106 inclusive all in a manner as
previously explained in detail. Each upper pusher arm has a
resilient gripping action with its particular coil spring by reason
of the coil gripping elements 91 which are opened by the cam bars
98 for encircling a coil. Upon retraction of the cam bars the
elements 91 close and grip the coil. This action is very desirable
since it provides the necessary control of the coils as they are
caused to enter the dies.
With the return reciprocating stroke of the upper pusher arms, the
elements 91 open against the tension of the resilient springs 92.
This action automatically releases the grip on the coils and as a
result the coils are left on the dies in the desired position
thereon for the final operation namely the feeding of the helical
coil for connecting the top and the bottom convolutions. After the
coils have been pushed off the turntables they are lowered and also
rotated to their original position. The turntables 47 and their
supporting means, the adjustable gear 70, the racks 72 and 75,
power cylinder 81 and the top slide plate 80 all comprise a unitary
structure which is bodily moveable up and down by the power
cylinders 58.
The positioning pins 40 and their mode of operation is an important
feature of the present invention. Energization of the solenoids
takes place in succession as regards the longitudinal row and in a
direction opposite to movement of the belts. Thus actuaction of the
pins stops movement of the coils one at a time and positions each
coil in desired spaced relation in its row although the belts
continue to move. When a coiler is employed as herein shown the
belts have intermittent movement to synchronize the rotation of the
transfer drum with the operation of the coiler. However it is
possible to produce the coil springs at locations removed from the
present apparatus and manually place the coils respectively on the
flat magnetic surfaces of the transfer drum. When the coil transfer
apparatus is operated in this manner the belts can have continuous
movement instead of intermittent movement.
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