MXPA95001320A - Method and apparatus for manufacturing mattresses and drums of reso - Google Patents

Abstract

Disclosed is an apparatus for forming springs for incorporation into a lower spring mattress. The device includes the use of spare gears to facilitate the manufacture of a variety of sizes of spring interi

Description

METHOD AND APPARATUS FOR MANUFACTURING SPRING MATTRESSES AND DRUMS TECHNICAL FIELD This invention relates generally to the manufacture of spring mattresses and drums, and particularly relates to the manufacture of springs for use in constructions of imprisoned roll or "Marshall". BACKGROUND OF THE INVENTION In the prior art, it is known to form springs from wire, and insert said springs into ropes of imprisoned or "Marshall" type rolls. An example of such construction is illustrated in U.S. Patent Nos. 4,234,983 and 4,986,518 issued to Stumpf (hereinafter incorporated by reference). The methods and apparatus for providing such constructions are disclosed in U.S. Patent Nos. 4,439,977 and 4,854,023 issued to Stumpf (hereinafter incorporated by reference). Said elongated constructions, sometimes called imprisoned roll ropes, may be mounted in an inner spring construction as disclosed in U.S. Patent Nos. 4,566,926 and 4,578,934 issued to Stumpf (hereinafter incorporated by reference). Although the above inventions provide effective use, the need for a method and apparatus for providing such internal spring constructions in a variety of roll sizes and heights to satisfy a buying public that has recognized a variety of mattress preferences has been recognized. . In order to minimize inventory expenses to provide a truly "produced as required" product, a need was recognized to provide a single manufacturing process that could be adapted to produce a variety of internal spring construction sizes. To achieve this goal, a need has also been recognized for a spring manufacturing apparatus that can manufacture springs having different wire lengths, different spring heights and different spring widths, with a minimum of exchange difficulties. Summary of the Invention The present invention overcomes the inadequacies of the prior art by providing an apparatus for manufacturing springs for an internal spring construction, which provides an optimization of the size of the spring at the rate of production. This is achieved in part by providing replaceable gears and interchangeable and adjustable spacer cams corresponding to a particular spring size. Therefore, it is an object of the present invention to provide an improved mattress construction. It is a further objective of the present invention to provide an improved method for manufacturing mattresses. It is a further object of the present invention to provide an improved mattress manufacturing apparatus that is cost effective in its operation. It is a further object of the present invention to provide an improved mattress manufacturing apparatus that is cost-effective in its maintenance. It is a further object of the present invention to provide an improved mattress manufacturing apparatus that is simple in operation. It is a further object of the present invention to provide an improved mattress manufacturing apparatus that is readily compatible with other manufacturing devices. It is a further object of the present invention to provide an improved apparatus for making mattresses that is reliable in its operation. It is a further object of the present invention to provide an improved mattress manufacturing apparatus that can be operated with minimal operator supervision. Other objects, features and advantages of the present invention will become apparent upon reading the following detailed description of the preferred embodiment of the invention when taken in conjunction with the drawing and appended claims.

Brief Description of the Drawings Figure 1 is a pictorial view of a wire forming apparatus in accordance with the present invention, which faces the front left corner of the device. Figure 2 is an illustrative view of a prior art power transfer scheme. Figure 3 is an illustrative view of a power transfer scheme in accordance with the present invention. Figure 4 is an isolated view of a portion of the apparatus of Figure 1. Figure 5 is an isolated view of a top wire feeder roll assembly. Figure 6 is an isolated view of a lower wire feeder roll assembly. Figure 7 is an isolated view of a wire straightening assembly. Figure 8 is an isolated view of a section in cross section of a top or bottom feed roll. Figure 9 is an isolated view of a cross-sectional section of an upper and lower feeder roll with wire between them. Figure 10 is a pictorial view of a roll formed by the apparatus of Figure 1.

Figure 11 is a side plane view of a roll formed by the apparatus of Figure 1. Figure 12 is an illustrative view of the link between the master gear and the forward sliding bearing of the top feeder roll shaft. Figure 13 is an illustrative view of the wire that passes through the feed rolls and is bent to become a spring. Figure 14 is an isolated view of the link between the main wheel and the roll diameter roll. Figure 15 is an isolated view of the link between the main wheel and the separation bar. Figure 16 is an isolated view of the link between the main wheel and the wire cutting knife. Figure 17 is a table illustrating various possible gear change rates under the present invention. Figures 18A and 18B are a pair of tables illustrating the different processes that vary due to the use of the different rates of gear change. Figure 19 is a view of the imprisoned rolls. Figure 20 is a view of an inner spring construction. Figure 21 is a view of a pinched roll mounting machine.

Detailed Description of the Preferred Incorporation Reference is now made to the figures, in which the numerals designate common objects throughout the various views. Construction and General Operation Reference is made to the general operation of the method and apparatus in accordance with the present invention. Referring now to Figure 1, the wire is pulled from a roll of wire (not shown) and straightened by passing it through the wire straightening station 70. The wire is fed through two upper wire feeder rolls and lower cooperative 44, 25, respectively, which are combined periodically to grasp and feed the wire at the selected distance. The wire is bent and cut to result in a finished wire spring as shown in Figures 10 and 11. Referring now to Figure 3, the replacement gears 24, 51, attached to a feed roll shaft lower 22, and a transverse axis 52, respectively, allow adjustment of the wire feed for each wire forming cycle. This should be distinguished from the prior art system shown in Figure 2. Particular Construction and Operation For purposes of this analysis, the spring forming apparatus 10 will be considered to have a "forward", "posterior", "left" and "right" side. ", and is in relation to three mutually perpendicular axes, which comprise the axes" X "," Y ", and" Z "(See Figure 1). In operation with the wire forming apparatus, it will be understood that, if an observer sees the front of the apparatus, the operator will see the initial wire feed to the machine from right to left along the "Y" axis, leaving the springs formed there along a path that comes towards the observer and along the "Z" axis. General Power Transmission As illustrated particularly in Figures 3 and 4, power is supplied by an electric motor and a gearbox assembly 12 or other power source. A chain 14 transfers power from a wheel gear 13 mounted on the electric motor to a lower feed roll shaft wheel gear 16 mounted approximately on the end of a lower feed wheel shaft 22, which is part of a lower feed roll shaft assembly 20. The lower feed roll shaft 22 is rotatably mounted relative to a frame 20 by bearings as is known in the art, such that said lower feed roll shaft preferably has a stationary rotating shaft relative to the frame 11 and substantially along the "Z" axis.

A positive gear 24 is fixed approximately at the rear end of the shaft of the lower feed roll 22. This gear 24 drives an engagement gear 51 fixed to the transverse shaft 52. The transverse shaft 52 is rotatably mounted in a transverse shaft housing 55 by means of typical saddles and substantially along the "Z" axis. The housing of the transverse shaft 54 is fixed to the frame 11. A pinion gear 53 is fixed approximately at the front end of the transverse shaft 52. This pinion gear 53 drives a main wheel 23, which is rotatably mounted by means of a bearing on the axis of the lower feed roll 22. It is very important to note that the main wheel 23 is not fixed on the axis of the lower feed roll 22, but is allowed to rotate relatively with respect to the axis of the lower feed roll 22. As discussed is more detail to sontinuasión, the main wheel 23 acts as a kind of timing device, in the sense that the timing of the prinsipal wheel 23 determines the temporization of wire feed , the formation of springs, the cutting of springs and the timing of other actions. Mounting the Roll Eie Upper Feeder Referring now to Figures 3, 5 and 6, an upper feeder roll shaft 42 is rotatably mounted with respect to the frame 11 by a pair of bearings that allow the axis to pivot in a certain way as analyzed. in detail later in this application. The feed is transferred from the shaft of the lower feed roll 22 to the shaft of the upper feed roll 42 by interacting wheel gear devices 21, 41, fixed approximately at the rear end of the lower and upper feed roll shafts, 22 , 42, respectively. Approximately at the front end of the upper feed roll shaft 42 an upper feed roll 44 is fixed. As discussed in detail later in this application, the shaft of the upper feed roll 42 periodically pivots upward, causing the roll of upper feed 44 moves upward and away from the upper feed roll 24, so that even when the two rolls are rotating, a space between them prevents the two rolls from grasping the wire. However, when the axis of the upper feeding roll is in its "downward" position, the feeding rolls are used to grip or "bite" the wire between them, to facilitate feeding the wire for later formation and cut. Lower Feed Roll Shaft Assembly With reference particularly to Figure 6, the lower feed roll shaft assembly 20 includes a lower feed roll shaft 22, a wire feed roll 24 fixed to the axis of the lower feed roll 22, a pair of bearings 21, a prinsipal wheel 23 having in it a bearing. a separating cam 25 fixed in relation to the main wheel 23, a fixed wire feeder cam 26 fixed in retraction with the main wheel 23, a movable wire feeder cam 26 fixed adjustably in relation to the main wheel 23, a mobile feeder cam of saber 27 set adjustably with respect to the main wheel 23, a cutting knife driver 28 appended to the front face of the main wheel 23, and a timing gear (not shown), attached and attached to the rear side of the main wheel . The timing gear drives a timing shaft 83 (See Figure 14) which controls the timing of several automatically driven processes downstream of the spring formation, including roll compression, roll insertion in the tissue pinch, feeding of the imprisoned tissue, the sealing of the imprisoned tissue. Therefore, it can be seen that the timing of these pneumatic operations depends on the speed of the main wheel. The axis of the lower feeder roll 20 is rotatably mounted relative to the stationary frame 11.

Wire Feed The wire to be used in the formation of the spring is a typical spring wire. One type of wire is an upholstery wire that has a tensile strength property of 270,000-290,000 pounds per square inch. The Straightener Referring now to Figure 7, there is shown a wire straightening assembly 70, including a wire straightening frame 71, and cinderellating rollers 72. Each straightening roller 72 is mounted on a corresponding roller block 75 that it can be slid in relation to the wire straightening frame 71. The adjustment and fixing of the corresponding roller blocks 75 to the wire straightening frame 71 is done by roller screws 73. As can be understood, the relative position of the rolls straightening 72 allows an operator to cause the wire coming from the bovine roller to straighten before rolling and cutting. Grooved Rollers V As discussed above, the two wire feed rollers 24, 44 bite the wire to feed it. As shown in Figure 12, two V-shaped grooves are drawn into one of the rollers 24, 44. Referring to Figure 8, the cross-sectional area of one of the grooves of the one of the arms is shown. wire feed rollers. As can be seen under the light of Figure 9, the V-shaped transverse section of the channel allows different wire gauges to be used. The two calibers shown in Fig. 9 are 0.086"and 0.056" in diameter. The two sockets are on each roller to allow any of these to show up in the process of a groove becoming worn. Only one asanaladura per roller is used during the operation. The Upper Front Sliding Bearing Assembly With reference now to Figures 1 and 12, the upper front bearing assembly 30 operates to allow the front end of the upper front feed roll shaft 42 to be lifted, to allow the upper feed roll 44 is raised in relation are the lower feeder roll 24, to facilitate the selective feeding of the wire caught between them. The upper front bearing assembly 30 includes a sliding bearing block 31 in which a roller bearing is mounted. The bearing block 31 is slidably mounted in relation to the frame 11 along an axis that is substantially vertical. The block of sojinete is twisted of springs of such way that the block deviates to a position "hasia arriba", posisión in the sual the wire is not grasped by the two feeding rollers. The slab block 31 is indexed periodically in a "down" position, which facilitates the periodic feeding of the wire through the two rollers. This indication is initiated through a pair of wire feeder cams 26, 27, which are fixed in recession are the main wheel (not shown in Figure 12), and are allowed to rotate with the prinsipal wheel 23 in recession are the lower wire feeder shaft 22. The pair of wire feeder cams includes a fixed wire feeder cam 26 and a movable wire feeder cam 27. These two cams provide a rolling path for a single member of roller 32, which is it orients the spring against the cams and facilitates upward and downward movement of the roller member as discussed in detail below. The roller member 32 is rotatably mounted along a substantially horizontal axis at the rear end of an elongated pivot arm 33. This pivot arm 33 is pivotally mounted in relation to the frame 11 along a substantially horizontal axis at the pivot point 34. The forward end of the elongated pivot arm 33 is attached to the upper front bearing block 31, such that the downward movement of the roller member 32 results in an upward movement of the bearing block. 31 (as well as the upper feeder roller). The fixed and mobile cams 26, 27 are substantially similar in shape. The function of the front (fixed) cam 26 is to cause the thrust cam 32 to move from a higher position (not the feed blade) to a lower position (supply saber), which is hesho to allow the thrust cam to take the form of a ramp upward to the upper side of the cam 26. The thrust cam passes through the upper side of the cam 27, where a The long one is allowed to acquire the ramp downwards depending on the position of the mobile cam 27. As can be seen, the spherical bearings are used on the back of the upper and lower feeder roller shafts, and on the front of the lower feeder roller shaft. Wire Formation General Aspects With reference now to Figure 13, the wire 15 is fed from the wire feeder rollers 44, 24, through a fixed forming pipe 17, which serves as a constant positioning guide for the wire. The wire is then folded down and in a curve through a bending roll 81, also known as a roll of diameter 81. As will be discussed later in greater detail, this action defines the "diameter" of the roll spring, which it varies along its length. After being bent by the roller of diameter 81, the wire is passed to the side of a separating lever 9i, which is analyzed in greater detail later, it is movable along a substantially horizontal axis along the direction " Z ". The further the separating cam 8i moves forward the more the winding steps of the roll spring are separated. It can be understood that for a roll spring that is shown in Figures 10 and 11, the twist windings are separated more in the center of the spring than at their ends. Mounting the Roll Diameter 80 It can be understood that for the rolls shown in Figures 10 and 11, the diameter of the roll on its face is greater than the diameter at its ends. For that purpose, several bending sanctities are provided in this direction. The roll diameter assembly 80 provides a fold bend in the wire that determines the width (at the ends in the central part) of the springs that are manufactured. With reference now also to Figure 14, the construction and operation of the roll diameter assembly 80 is now analyzed. The feed and timing are obtained from a timing gear (not shown, attached to the back of the wheel main) driving the start gear 82, which is fixed to the rear end of a timing shaft 83, which is rotatably mounted along the "Z" direction with respect to the frame il by bearings as is conjoined in the art. . A pair of cams 84, 85, are assembled to be adjustable according to the timing axis. These cams engage a push cam 86, which is rotatably mounted with respect to a pivoting rod 87 which is pivotally mounted with frame to the frame 11 along a pivot axis "from front to rear" substantially vertical parallel to the direction " Z ". As the push cam 86 is moved up and down the main cam, the pivot rod 87 is also pivoted up and down. The upper face of the pivot bar 87 includes a channel that slidably accepts a sliding bearing member 88, which resets the lower end of an adjusting screw having a handle 89. A block 76 threadably accepts the adjusting screw approximately in its central part, and this block 76 is fixed to an angled rod 77 which is fixed to a pivoting block 78 which is fixed approximately at the rear end of a roll diameter shaft 79. The roll diameter shaft 72 is rotatably mounted to along an axis along the direction "Z" by means of bearing (as coned in the art) in recession are the frame 11. A cam-assembling member 75 is fixed at the front and at the side of the diameter shaft of roll 79. This member is pivoted along a sustantially vertical axis along the "Z" direction to allow the roll diameter roll 81, rotationally attached to it, moves to various bending positions between an "inner extreme" position (more bending of the wire results in a smaller diameter) to an "outermost" position (the smaller bending of the wire results in a larger diameter) . A spring 74 is directed towards the roller towards the "extreme outer" position. Roller Separator Assembly The roller separator assembly 90 provides a varying bending action on the wire that helps determine the length of the roll spring. Again, with reference to Figures 10 and 11, it can be seen that it is often desirable to provide a roll spring that includes a full revolution at the top and bottom ends 8 of the spring; this is especially desirable if the spring is to be collated on a flat surface. However, no overlap is desired in the sentral part 9 of the spring, since it would prevent the springs from being linked or "hooked". Therefore, it can be understood that it is desirable to provide a variable bending action on the wire to limit said configuration. Referring now to Figures 14 and 15, the movement of the spacer bar 92 along the "Z" direction is now analyzed. As previously discussed, a replaceable spacer cam 25 is fixed in relation to the main wheel, and is allowed to rotate with the front wheel in relation to the lower axle of the lower wheel 22 * As the spreader cam 91 rotates, ngrana to üfi pair of thrust cams 94, 95, one of which 3 is adjustable to an average porssion of the pivoting spacer 96. As will be understood, the thrust amounts are engaged and disengaged. separator 91, the separating bar 9i moves outwardly and inwardly, respectively, to cause a separating action to be imparted on the springs. Referring now partially to Figure 15, the "right" end of the link of the pivoting spacer 96 is attached to a spherical joint assembly 97, which is mounted on an adjustment block 98 that is adjustable from front to back, to enable that the vertical pivot point of the pivot spacer link moves forward or backward. The "left" end 112 of the link of the pivoting spacer is reduced to a rectangular cross section, which fits within a transverse groove 11 extending along the elongate spacer shaft 110. The shaft 110 is slidably mounted in relation to the frame 11 by bushings (not shown), in such a way that the shaft can slide along the longitudinal axis, which is along the "Z" direction. The spacer bar 92 is mounted on the front end of the shaft 110 by means of a mount. The spacer shaft 110 is sprung by springs towards its retracted position, at the rearmost part by means of a tension spring 113. As can be understood, the separating cam engages the two thrust cams, the 96 tends to pivot relatively towards its right end , the left end 112 causing 110 to move forward along the "Z" direction (by the thrust action of cam 25) and backward (by tension or spring 113). This causes the spacer bar 92 to be pushed equally forward (more separation) and backward (less separation or lack thereof). It should be understood that the use of two thrust cams allows an "effective thrust cam surface" which is wider and adjustable, which allows some adjustment of the action of the thrust cam by the relative movement of the two thrust cams. , 95, one with respect to the other and along the pivotal link 96, since the preferred incorporation of the push cam 25 is not adjustable, although it is replaceable with a cam having a different profile to fit a pair of gears of spare parts. However, as discussed in more detail below, the spacer cam is replaceable, since it may be necessary to change the spacer cam when the spare gears are changed to provide a different cam profile corresponding to a different spring profile. - A shield 67 (shown in Figure 1) is fixed in a frame in relation to the frame to "take away the second wire ring out of the way of the spacer bar." However, as discussed below with greater detail, The separating cam is replaceable, and it may be necessary to change the separating beam when the replacement gears are changed to provide a different spring shape. Wire Cutting Referring now to Figure 16, the wire lot process is analyzed. As previously discussed, a cutting wire cam 28 is collated on the front face of the main wheel. The cam of the cutting cushion 28 comes into contact periodically with the rear end of a serrated knife shaft axis are springs 101, which causes a base sushillo 102 to wire the wire that passes through the apparatus. After sorta the wire, a spring derives the shaft back to its "retracted" position. The cutting knife is replaceable. Related Devices Referring now to Figure 21, a pinching apparatus is shown, which resets rolls formed in the apparatus 10, and places the roll springs in the pinching material, from such a handle that a retained wire rope is propitiated as The one shown in Figs. 9 or A- The cords may be joined to form an internal spring construction as shown in Fig. 20. Said processes are disclosed in U.S. Patent Nos. 4,234,983, 4,439,977, 4,566,926, 4,578,834, and 4,854,023, awarded to Stumpf, all incorporated herein by referensias. Timing In the preferred embodiment, the timing axis includes cams that engage corresponding switches. Each of these switches causes a specific type of assurance that is part of the general invention. In the preferred embodiment, the switches open and close air valves to allow pressurized air to pneumatically push or control these locations. An assión is the roll compression grip of the rolls downstream. In order to insert the rolls into the tissue imprisonments, it is often necessary to compress them. An assión is the action of the insertion of rolls of the squeezed rolls in the imprisonments. An assión is the action of the thermal welding or the supply of another way of roll imprisonments. An action is the action of indicating the trapping tissue after the rolls have been inserted.

For the sake of the present, see more examples of roll-up, roll insertion, weaving soid, weaving g ying, and tempera ture r i ng to the shaft assembly give tempbfizacieíi. -? ot io táñtß also püédé éfitehderse what li d§o of the éhgráfiájeá de íri6ai .bib péL-kidneyite 8a- bio eñ iá feeding of wire for paira liña taiá given to which feltos aábÉ occur; The relative timing of vfios pLfdtígsdi of cañfürmidad Cori la ihv§R8ioñ §i fflUSSfcfcañ ' «By means of páüicas fi.d§ttada§ éfi the Fidüfás i§á and i§b < jur -I analyze Coh Myot detail below- Rates of Gears of Change and Gear Shift Separator As previously discussed, the gears of -rgcafnbio can be replaced in equal pairs. Each equal pair is accompanied by a particular associated spacer cam 25, which is replaced with the replacement gears. Referring now to Figure 17, the different rates of the spare gears that can be used are shown. The solumn one, entitled "Basic Rates of Pinion / Main Wheel ", establishes the rotary radius between the pinion and the prinsípal wheel: three revolutions of the pinion gear by a single revolution of the main wheel, column two, entitled '? NgráliéS of the e e franSversál, impülSados-Impulsados'' , establishes §1 number of teeth in the two replacement ehdranájes. For example, in the case of the line, the replacement gear of the shaft of the lower feeder roll has 50 teeth, and the replacement gear on the transverse axis has 70 teeth. The rotation rate of the lower aligment roll axis with respect to the rotation of the main wheel (an operating block of the spring forming apparatus) is i; 4 / 1.0, which is established in the following column entitled "Transverse Axis Fees". The "Total Rate", established in the next column, is the rate at which the axis of the lower feeder roll rotates in relation to the front wheel. Again taking the first example, the shaft of the lower feeder roll rotates 4.2 times by a single rotation of the replacement gear. This graph illustrates an important feature of the invention. When changing the spare gears, the number of times that the axes of the feeder roller rotate per cycle can be modified. A distinctive advantage is that more wire can be fed per cislo, thus providing larger rolls if necessary. As discussed above, the largest rolls currently have a higher demand for the users. The advantage of providing additional wire feed is illustrated in reference to Figures 18a and 18b. The explanation of the terms used in Figures 18a and 18b is as follows. "Feeding Wire" is the process of feeding wire to cover the sufficient amount of wire. As it has been analyzed previously, this depends on the speed of the wire shaft of the wire. The wire cut is the thread to cut the wire to make the formation of a wire. The frequency of this depends on the speed of the wire. turn of the main wheel and occurs once per cycle. "Letting the Roll Fall" is the process of removing the roll from its cutting position to its position on the surface with roll pressure and below a roll compression head. The frequency of this depends on the rotation speed of the main wheel and occurs once per cycle. "Roll-Down Compression" is the process of causing roll compression to go down. "Rollo Compression Hasia Arriba" is the inverse of the previous process. The freshness of this depends on the rotational velocity of the timing axis (which is the same as that of the main wheel), and oscillates once per cycle. "Insert-Roll-In" is the process of inserting a compressed roll into layers of tissue imprisoned by the use of an inser- tion head. The freshness of this depends on the speed of rotation of the timing axis (which is the same as that of the main wheel), and only once per stroke.

"Insertion of Rollo-Afuera" is the process of removing the inSersora knowledge from the tissue webs. The ftesuehsia of éto depends on the speed of rotation of the axis of tempmpizasion (which is the same as that of the ptihsipalj > wheel and occurs once per sislo. "index" is the process of indicating the fabric with one roll width at a time.) The freshness of this depends on the rotational velocity of the axis of temporization (which is the same as that of the main wheel), and occurs once per cycle. "U / S Sealing" is the process of welding the fabric to form at least part of the tissue's imprisonment. this depends on the rotation speed of the timing axis (which is the same as that of the main wheel), and occurs once per cycle, as can be seen from a comparison of the two Figures 18A and 18B, the use of the replacement gears and a formation cam allows the provision of a Total Rate (see Figure 17) of 3.42 / 1 instead of the previously "locked in" rate of 3.00 / 1. Therefore, for a given cycle the feeding time of the "wire feed" process can be cut out for a given amount of fed wire, as the wire can be fed at a higher rate for a given speed of the main wheel. This in effect causes a "domino" effect, in the sense that by adjusting elements such as 27, 84, 85, 94 and 95, the other processes can be given more time, which is desirable in the sense that one of these processes depends on the severity, namely, the process of Letting the Roll Fall. It has been found that in many instances this process is the limiting process. Therefore, if any time can be "borrowed" from any other process (for example, the Cable Feed Cycle) the apparatus 10 can be tuned at an advantageously high rate, improving the production rates. In this case, this allows an optimization of the size of the spring with respect to the production rate. Conclusion Therefore, it can be seen that the present invention provides an improvement over pre-ballast by providing an apparatus for manufacturing springs for an inner spring construction, which provides an optimization of the spring size with respect to the production rate. It is to be understood that although musho of what is discussed herein relates to springs for mattresses or spring drums, it should be understood that the present invention can also relate to springs used in other constructions, such as cushions. Although this invention has been described in specific detail with reference to the preferred embodiments, it will be understood that many variations and modifications may be made within the spirit and scope of the invention. Coffid Be distracted by the claims ahe <

Claims (20)

1. NOVELTY OF THE INVENTION Having described the foregoing invention, the content of the following CLAIMS is claimed as property 1. An apparatus for forming springs from wire and inserting said springs in a mattress, comprising: a) an insert assembly for squeezing the coil springs, inserting springs into the imprisoned fabric, and sealing said springs within said fabric to provide a cord of imprisoned roll; b) a winding assembly for forming wire in roll springs, comprising: a frame; a lower feeder roller shaft rotatably mounted with respect to said frame; a lower feeder roller attached to said lower feeder roller axis; an upper feeder roller shaft rotatably and pivotally mounted with respect to said frame; An upper feeder roller attached to said lower feeder roller axis, collated from the upper feeder roller, is respected to the lower feeder roller such that said upper and lower feeder rollers are configured to grip the wire between them when the upper and lower feeder feeder rollers are disposed. they are in a relative first position, and configured to release the wire between them when said upper and lower feeder rollers are moved from said first relative position to a second relative position; devices for rotating said upper feeder roller shafts such that the wire is fed at a directly proportional rate of rotation of said lower wire feeder shaft when said upper and lower feeder rollers are in said first relative position; an upper shaft indexing assembly configured to allow said upper and lower axes to be periodically joined and separated, causing said upper and lower feeder rollers to be joined correspondingly to said first relative position and spaced apart to said second relative position, to allow the wire colosed between dish feeder rollers are seized and released accordingly; a first reshaping gear mounted removably on the lower shaft of the feed roller; A transverse shaft rotatably mounted are relasion to the frame; a second reshaping gear removably mounted on a transverse axis; a rotating mounted main wheel is relasión to disho framework; a wire feeding assembly for overriding the grip and the release of said wire by said upper and lower feeder rolls are respect to the rotation of the main wheel; a wire cutting assembly for providing periodic cutting of said wire, said periodic cutting being synchronized with the rotation of said main wheel; a wire diameter forming assembly for providing the periodic formation of wire diameter, said periodic shape being dimensioned with the rotation of said main wheel; a wire separator assembly for providing the periodic separation of said wire, said periodic separation being synchronized to the rotation of said main wheel; and a timing axis assembly including a timing shaft rotatably mounted with respect to said frame and rotatably driven at a speed directly proportional to that of said main wheel, said timing axis being configured to provide timing signals to said timing assembly. rope, in such a way that the steps of said compression, insertion and roll sealing are all synchronized with said timing axis, in such a way that said replacement gears can be selssioned and replaced to allow the wire feed rate to be modified accordingly. for a given rate of rotating velocity of disha wheel prinsipal.
2. 2. The apparatus claimed in the Claim 1, wherein said timing axis assembly comprises a plurality of cams and triggers that cause signals associated with the compressed air to initiate said compression, insertion and sealing steps.
3. 3. The apparatus that is claimed in the Keívindisasióh 1, where the timing axis is driven to the same rotating velocity as the prinsipal wheel.
4. 4. The apparatus claimed in Claim 2, wherein the timing axis is driven at the same rotational speed as said primary wheel.
5. 5. The apparatus claimed in Claim 1, wherein the upper and lower wire feeder rollers include one a V-shaped annular groove having sides each being a portion substantially subtract. The apparatus as claimed in Claim 4, wherein the upper and lower wire feeder rollers include a V-shaped annular groove having sides each with a substantially straight portion. 7. The apparatus claimed in Claim 1, wherein said main wheel is rotatably mounted on the lower feed roller shaft. 8. The apparatus claimed in Claim 1, wherein said wire separator assembly includes a fixed replaceable separating cam relative to said main wheel, said separating cam being capable of being replaced together with said replacement gears. 9 -. 9 - EÍ apatato what is relied on in the Claim 1, wherein the rate of teeth that are disposed of On said first spare gear with respect to the rate of teeth in said second spare gear is 50 to 70. The apparatus claimed in Claim 1, wherein the rate of teeth which are ensued on said first gear of replacement with respect to the rate of teeth found in said second replacement gear is from 55 to 65. 11. The apparatus claimed in Claim 1, wherein the rate of teeth lying on said first gear of replacement with respect to the rate of teeth found in said second spare gear is from 52 to 68. 12. The apparatus claimed in Claim 1, wherein the rate of teeth lying on said first spare gear. with respect to the rate of teeth found in said second replacement gear is from 54 to 66. 13. The apparatus claimed in Claim 1, wherein the rate of teeth that are on each other. The first gear of reshuffle are respectable to the rate of teeth that are in said second gear of change is 56 to 62. 14. The apparatus as claimed in Claim 1, wherein the rate of teeth on said first replacement gear with respect to the rate of teeth in said second replacement gear is 66 to 54. 15. A apparatus for forming springs from wire, comprising: a frame; a winding assembly for forming wire in roll springs, comprising: a frame; a lower feeder roller shaft rotatably mounted with respect to said frame; a lower feeder roller attached to said lower feeder roller axis; an upper feeder roller shaft rotatably and pivotally mounted with respect to said frame; an upper feeder roller attached to said lower feeder roller axis, said upper feeder roller positioned with respect to said lower feeder roller such that said upper and lower feeder rollers are configured to grip the wire therebetween when said upper and lower feeder rollers they are in a relative first position, and configured to release the wire that lies between them when said upper and lower feeder rollers are moved from said first relative position to a second relative position.; devices for rotating said upper feeder roller shafts in such a way that the wire is fed at a proportionally proportional rate of the rotation of the lower wire feeder shaft while both upper and lower roller rollers are in said relative position; an indexer assembly of upper shaft configured to allow said upper and lower shafts to be coupled and spaced apart, causing said upper and lower feeder rollers to be correspondingly joined to said first relative position and sequestered to said second relative position, to allow the wire placed between said feeder rollers are grasped and released correspondingly; a first replacement gear removably mounted on said lower feed roller shaft; a transverse shaft rotatably mounted relative to said frame; a second spare gear mounted removably on a transverse axis; a rotating mounted main wheel are related to each frame; a wire feeder assembly for overriding the grip and release of said wire by said upper and lower feeder rolls with respect to the rotation of said primary wheel; a wire frame assembly for providing periodic cutting of said wire, said periodic cutting being synchronized with the rotation of said main wheel; a wire diameter shaping assembly for pto-rotating the periodic diameter shaping of said wire, said periodic diameter formation being synchronized with the rotation of said main wheel; and a timing shaft assembly including a timing shaft rotatably mounted with respect to said frame and rotatably driven at a speed directly proportional to that of said main wheel, such that said spare gears can be selected and replaced to allow the wire feed rate is correspondingly modified for a given rate of rotational speed of said main wheel. 16. The apparatus claimed in the Claim 15, wherein the rate of teeth lying on said first spare gear with respect to the tooth rate in said second replacement gear is 50 to 70. 17. The apparatus claimed in FIG. Claim 15, wherein the rate of teeth that are spread over the first reshaping gear are respectable to the rate of teeth that are in said second replacement gear is 55 to 65. 18. The apparatus claimed in FIG. Claim 15, wherein the rate of teeth on said first replacement gear with respect to the rate of teeth in said second replacement gear is from 56 to 62. 19. The apparatus claimed in FIG. Claim 5, wherein the rate of teeth on said first replacement gear with respect to the rate of teeth in said second replacement gear is 66 to 54. 20. An apparatus for feeding wire, comprising; a frame; a lower feeder roller shaft rotatably mounted with respect to said frame; a lower feeder roller mounted on said lower feeder roller axis, including a V-shaped annular groove having sides each having a substantially straight portion; an upper feeder roller shaft rotatably and pivotally mounted with respect to said frame; a top feeder roller mounted on said top feeder roller shaft, said lower feeder wire roller including a V-shaped annular groove having sides each having a substantially fine portion, said upper feeder roll positioned with respect to said roll lower feeder such that said upper and lower feeder rollers are configured to grip the wire therebetween when said upper and lower feeder rollers are in a relative first position, and are configured to release the wire that lies between them when said rollers upper and lower feeders move from said first position relative to a second relative position.