US3770180A - Apparatus for manufacturing box springs - Google Patents
Apparatus for manufacturing box springs Download PDFInfo
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- US3770180A US3770180A US00218843A US3770180DA US3770180A US 3770180 A US3770180 A US 3770180A US 00218843 A US00218843 A US 00218843A US 3770180D A US3770180D A US 3770180DA US 3770180 A US3770180 A US 3770180A
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- frame
- slat
- stapling
- spring
- cross
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23Q—DETAILS, COMPONENTS, OR ACCESSORIES FOR MACHINE TOOLS, e.g. ARRANGEMENTS FOR COPYING OR CONTROLLING; MACHINE TOOLS IN GENERAL CHARACTERISED BY THE CONSTRUCTION OF PARTICULAR DETAILS OR COMPONENTS; COMBINATIONS OR ASSOCIATIONS OF METAL-WORKING MACHINES, NOT DIRECTED TO A PARTICULAR RESULT
- B23Q7/00—Arrangements for handling work specially combined with or arranged in, or specially adapted for use in connection with, machine tools, e.g. for conveying, loading, positioning, discharging, sorting
- B23Q7/06—Arrangements for handling work specially combined with or arranged in, or specially adapted for use in connection with, machine tools, e.g. for conveying, loading, positioning, discharging, sorting by means of pushers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
- B27F—DOVETAILED WORK; TENONS; SLOTTING MACHINES FOR WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES
- B27F7/00—Nailing or stapling; Nailed or stapled work
- B27F7/17—Stapling machines
- B27F7/26—Stapling machines without provision for bending the ends of the staples on to the work
Definitions
- the apparatus handles the springs and frames upside down, the guns being lowered for loading with springs, and raised for firing.
- the gun muzzles are adapted to receive an inverted spring and to position it rotatively so that the staple when driven will encircle the cross-wire from which the spring is suspended on the gun.
- PATENTED NOV 6 I975 SHEET 7 BF 7 ouus UP BACKING BAR oovm TRIGGER BAR mm: moex IIIM
- This invention relates to the manufacture of box springs, by which term I mean to include not only box springs as such, i.e., upholstered spring constructions mounted upon flat wooden frames and usually employed upon a bedstead or bedframe as a foundation for a mattress, but also similar such upholstered constructions employed as bases of studio couches, upholstered sofas, upholstered chairs, and the like.
- the invention relates particualarly (1) to a method of assembling springs into a construction, i.e., the arrangement of individual coil springs into a series of rows in regular pattern by virtue of the attachment of such spring coils individually to a base frame of wood or the like by means of stapling; (2) to a special apparatus for carrying out the method; and (3) to a particular form of spring coil which is particularly adapted to the practice of the method.
- the apparatus of this invention utilizes the stapling technique to fuller advantage by coupling it with a specially designed cone coil so that each coil is securely anchored and positioned by a single staple.
- this special form of coil may be differentiated from others now in common use in that, at its small end, the final convolution terminates in a chordal element which extends across the end convolution approximately diametrically thereof.
- This chordal element or cross bar at the small end of the coil becomes not only the means for positioning and anchoring the coil on the wooden slat frame, but is also the means by which the coil is supported in the assembly apparatus, as well as the reference for orienting the spring coils rotatively so as to position properly the knots at their large ends for later assembly of the supporting face of the box spring construction.
- the above-described coil is placed over the nose of a stapling gun, the muzzle of which has been modified to receive the aforementioned cross bar at the small end of the cone coil in such manner that the staple when driven will encircle that bar approximately midway thereof.
- the stapling is preferably performed with the stapling gun pointed upwardly so that gravity holds the coil in place.
- the flat frame of the box spring is inverted and overhead, the assembly being made in the upside-down condition, the stapling gun with coil thereon being moved vertically upwardly with respect to the slat frame to position the coil thereon for stapling.
- the gun is then fired with sufficient force not only to drive the staple securely into the wood and into encircling engagement with the cross bar of the spring, but also to impress or to indent the cross bar itself firmly into the wood.
- the apparatus includes the vertically positioned upwardly directed stapling guns in ganged or banked array suitable for stapling at least one row of springs at a time to the base frame.
- the guns are mounted on a movable carriage which is moved by power from a lower loading position to an upper firing position, and the stapling guns are suitably powered from a common source and fired simultaneously by a common trigger control.
- the inverted slat frame moves in suitable overhead ways, and is bucked by a suitable backing arrangement at the stapling station, to which and from which each cross slat of the base frame is indexed in turn toreceive a row of coils.
- FIG. 1 is a fragmentary perspective view of a box" spring construction partially completed in accordance with the invention, showing the spring assembly at one corner of the box spring frame;
- FIG. 2 is a side elevational view of the basic elements of the assembly apparatus, illustrating the sequence of operations by means of which the spring coil is carried by the stapling gun upwardly to the slat frame and stapled thereto;
- FIG. 3 is a side elevational view of the overall apparatus showing a supply stack or magazine of the slat frames on the right, uppermost one of which is on the ways and in the position at which its leading cross slat awaits a row of springs at the stapling station at the far left;
- FIG. 4a is an elevational view of the stapling mechanism as the operator sees it, i.e., from the right-hand side of the mechanism as seen in FIG. 3, FIG. 4a showing the guns in retracted position and charged with spring coils sufficient for a box spring of less-thanfull width, and showing the overhead ways moved inwardly to accommodate the less-than-full-width slat frame;
- FIG. 4b is a similar but fragmentary elevational view of the mechanism shown in FIG. 4a, but showing the guns ready for firing, i.e., with the spring coils elevated into contact with the cross slat of the wood frame, and the overhead backing bars cammed into solid bucking or shock-receiving contact with the upper side of the slat;
- FIG. 5 is a fragmentary perspective view of the stapling mechanism as seen from the operators station, showing in greater detail the gun and its mounting, and the elevating and triggering mechanisms;
- FIG. 6a, FIG. 6b, and FIG. 60 are each enlarged, fragmentary sectional elevational views of the frame feeding or indexing mechanism, shown in the upper lefthand portion of FIG. 3, for positioning each successive cross slat of the box frame at the stapling station, FIG. 6a showing the end or leading cross slat positioned to receive its coils, FIG. 6b showing the slat frame in transit as the second cross slat of the frame is moved into the stapling station, and FIG. 6c illustrating the second cross slat at the stapling station, and illustrating as well how each succeeding cross slat of the frame is thereafter so positioned;
- FIG. 7 is an enlarged fragmentary end elevational view of the indexing mechanism seen from the exiting end of the apparatus, i.e., the left hand end as illustrated in FIG. 3;
- FIG. 8a is an enlarged fragmentary elevational view of a portion of the indexing mechanism, showing in particular the mechanism for ejecting a completed assembl
- FIG. Sb is an enlarged fragmentary view of the indexing apparatus showing the controller for the frame ejector of FIG. 8a;
- FIG. 9 is a diagram of the electrical circuit and controller by means of which the aforementioned individual operations are coordinated in an operating cycle.
- the spring coil 20 is best seen in FIG. 1. It is a somewhat modified cone coil in that its five and one-half convolutions do not decrease in diameter linearly but rather abruptly from the major diameter of the upper knotted convolution 22 to the main body of the coil, which is of substantially smaller and so nearly uniform diameter as to be almost cylindrical in appearance as compared with the usual cone coil. To those familiar with the spring art, it is apparent that this kind of coil exhibits a fairly abrupt change in load carry from an initial softness to a considerable stiffness as the first or closed convolution deflects sufficiently to bring the succeeding convolution of smaller diameter into contact with the load to be supported.
- chordal element or cross liar 26 which is approximately the length of the minor diameter of the coil and is positioned approximately diametrically of the bottom convolution.
- This chordal cross bar serves a number of purposes, not only in the construction of the box spring itself but also in the handling and the orientation of the coil by the assembly apparatus.
- the cross bar 26 at the bottom of the coil is at or near the central axis of the coil, and also lies in the plane that intercepts the knot 23 at the top convolution.
- the desired final position of the knot 28 may easily be derived from the bottom cross bar 26 as a reference, inasmuch as the muzzle of the stapling gun, as will hereinafter be pointed out in detail, is adapted to receive the spring coil in only one of two alternate positions displaced degrees from one another.
- the spring coil as is indicated in FIG. 1, is made so that the cross bar 26 and the knot 28 share a common plane with the central axis of the coil, and when, as later will be described, the muzzles of the guns are arranged to receive the cross bars of the coils to position them only crosswise of the cross slat 30 of the slat frame 32, it is apparent that the position of the knot 28 at the upper end of the coil must be either on one side or the other of the cross slat 30 or, stated with reference to the direction of movement of the slat frame 32 through the apparatus, must either be fore or aft, i.e., on the leading or trailing edge of the spring.
- the slat frame 32 comprises the leading end slat 30, narrower intermediate cross slats 3i, and a trailing end slat 33 (FIG. 8b only). These are nailed to longitudinal side rails 34, the ends slats and 33 each having a second layer 30a and 33a in a common plane with the side rails 34. In frames of greater width than the twinsize frame shown, a center rail would also be provided.
- the individual stapling guns 35 ganged for unison operation in the assembly apparatus are powered by air, as is conventional with commercial industrial staplers, and are arranged, as will be apparent from FIG. 4a, in a line abreast upon a vertically reciprocable carriage 36 which itself is powered to travel between a retracted, lower, coil-loading position, shown in FIG. 4a, and an upper or firing position, illustrated in FIG. 417.
- a particualrly unique feature of the gun itself is that its muzzle is equipped with a surrounding sleeve 38 which is preferably of a slippery material such as Nylon, Teflon, or the like, is generally cylindrical in shape and of a diameter slightly less than the minor diameter of the cone coil, and is chamfered or cone shaped at its upper end to facilitate the emplacement of the inverted cone coil thereupon.
- a surrounding sleeve 38 which is preferably of a slippery material such as Nylon, Teflon, or the like, is generally cylindrical in shape and of a diameter slightly less than the minor diameter of the cone coil, and is chamfered or cone shaped at its upper end to facilitate the emplacement of the inverted cone coil thereupon.
- each gun is adapted to receive over its muzzle sleeve 38 one inverted coil spring which may be positioned in one of two positions at the discretion of the operator, i.e., with the knots in one of two available positions displaced 180 from one another. It will further be apparent that if some orientation other than a trailing or leading position of the knots were desired, the same may be as well achieved by maintaining the same relative orientation of knot 28 and cross bar 26 as is illustrated in FIG.
- the combination of the cross bar 26 at the bottom or small end of the spring coil and the diametrical seat 440 on the muzzle sleeve 38 of the gun serve to determine the rotative displacement or orientation of the coil, and to maintain that orientation while the coils rise from the loading position of FIG. 4a to the firing position of FIG. 4b.
- FIG. 2 the inverted slat frame 32 is shown positioned for the connection thereto of the second row of spring coils, a first row having previously been stapled to the end or leading cross slat 30 of the slat frame.
- the gun 35 in lowered position corresponding to that of FIG. 4a is loaded with a spring coil 20 which is then elevated by upward movement of the gun to the broken line position of FIG.
- the firing of the stapling gun 35 is preferably done with force sufficient to impress or to indent the cross bar 26 at the bottom end of the spring into the surface of the cross slats of the frame, the impact of this force being sufficient also to cause a slight bending of the cross bar in a vertical plane (See FIG. 1).
- the legs 46 of the staples 48 are preferably chisel-shaped so as to be bent into a curved configuration upon entering the wood, thereby to prevent their unintentional dislodgement, and to anchor the springs 20 securely in place.
- the stapling is performed with the springs 20 and the slat frame 32 in an upside-down condition, thus to use the force of gravity to maintain the desired orientation of the individual coil springs with the muzzles 38 of the stapling guns.
- the stapling mechanism illustrated to the far left of FIG. 3 as well as in FIGS. 40 and 4b and 5, is carried on a stationary frame, which comprises a pair of spaced standards 50 which are weldments of steel plate connected together at their upper ends by the cross beam 44, which is of inverted T section, and at their lower ends by cross bracing 52 of any suitable configuration. Above the lower cross brace, the standards are also joined by a tubular manifold 54, which is connected to a source of pressure air, and to which the individual stapling guns 35 areconnected by suitable flexible hoses 56, (FIG. 5) the manifold chamber having a volume sufficient to ensure that the guns will be powered uniforrnly.
- the guns themselves are mounted upon the reciprocable carriage 36 which includes a pair of slide members 58, one at each end of the carriage, connected by a cross beam 60 upon which the stapling guns are firmly clamped at uniform height in bolted pillow blocks 62.
- Each slide member 58 is movable upon a vertical slide shaft 64 or way which is secured in brackets 65 affixed to the adjacent standard of the frame.
- Each slide 58 is provided on the side opposite the operators position with a rack 66 fixed thereon, and each rack is engaged with a pinion 68 secured to a cross shaft 70 extending between, and journaled in bearings in, the opposed standards 50 of the stationary frame.
- One end of the shaft 70 as seen in FIG. 3 and at the left hand side of FIG.
- a driven pinion 72 which is in turn engaged by a reciprocable rack 74 connected to the piston rod of a double-acting air cylinder 76, the rack 74 being backed on its side opposite its teeth by a roller 77 to take the side thrust of the toothed engagement.
- the guns are connected for unison firing by a common triggering bar 78 which is carried by and therefore moves with the gun carriage 36.
- the bar 78 is a square tube eccentrically mounted at its ends in bearings 79 on the slide members 58 so that when rocked, one of its corner edges engages the trigger 80 of each gun and causes the guns to tire in unison.
- the trigger bar is rotated by means of a double-acting air cylinder 81 mounted upon the carriage 36, and connected to a crank 82 on the trigger bar, causing the bar to rock when the piston of the firing cylinder is moved.
- the inverted slat frame 32 is not of itself equipped to resist unyieldingly the impact of the staple because, when the guns are elevated to emplace the inverted coils against the downward face of the inverted slat, the thenupward surface of the slat would be out of contact with the upper cross beam 44, and would be supported firmly only under the longitudinal side rails 34 (and center rail when present) of the base frame. (See FIG. 4,7). It is, accordingly, desirable to transmit the firm support of the upper cross beam 44 directly to the cross slats in order to buck the same when the guns 35 are fired.
- the backing bar 42 for bucking the cross slats, and the operating mechanism therefor, are best shown in FIGS. 4a and 4b, and in FIGS. 6a and 6c.
- the backing bars 42 are two in number, one on either side of the central feeding or indexing mechanism 83 by means of which the slat frame 32 is advanced through the apparatus.
- Each backing bar 42 is positioned in a slot 84 (FIG. 6a) in the flange of the inverted cross beam 44, and by means of lugs 86 is reciprocably mounted upon a pair of capped posts 88 each screwed into the upper side of the girder flange.
- the backing bars 42 are normally maintained in an upper or retracted position on the cross beam 44 by means of compression springs 90 which encircle the posts 88. When retracted, the lower edges of the bars 42 provide ample clearance for the passage therebeneath of the cross slats of the slat frame 32 as the same are being advanced by the indexing mechanism 83 with the ends of the cross slats 30 resting upon the angle-iron frame ways 92 seen in section in FIGS. 4a and 4 b, and in side elevation in FIG. 2 and in the several FIGS. 6.
- cam levers 94 To bring the backing bars 42 into supporting contact with the upper surface of a cross slat to resist the driving force of the staple, four cam levers 94, two for each backing bar, are ganged to a connecting rod 96 which in turn is pivotally connected to the clevis of the piston rod of a double-acting air cylinder 98 mounted at one end of the upper cross beam 44.
- the extension of the piston rod of the cylinder causes the connecting rod 96 to move from left to right, as there seen, rotating the several cam levers 94 clockwise to cam the backing bars 42 downwardly into bucking contact with the cross slat of the frame.
- the drive cylinder 98 for the backing bars 42 is connected to the operating valve that controls the drive cylinder 76 for elevating the gun carriage, so that pressure air is admitted to both simultaneously.
- the cylinder 98 is smaller in diameter as well as stroke, it completes its movement before the guns are fully elevated, assuring that the cross slat is solidly backed for the arrival of the guns and therefore solidly bucked for their firing.
- the ways 92 upon which the slat frame 32 advances through the apparatus are adjustably mounted upon the flange of the cross beam 44, being suspended therefrom on brackets 100 that are adjustably clamped to the flange by means of set screws (FIG. 2).
- the backing bar 42 is made adjustable in length by providing it with segmental engaging elements or shoes 102, which are attached to the reciprocable backing bar 42 by means of screws and which permit the convenient removal of a sizeable portion of the engaging edges of the bars to accommodate the twin size frame, or the complete replacement and substitution of different shoes in the event that other widths or slats arrangement of base frames is employed.
- the positions of the guns on the movable gun 36 can likewise be adjusted to control the intercoil spacing, as may be desired to accommodate other than the major sizes of box springs which will occupy the greater portion of the operating time of the apparatus.
- a stack or magazine 103 of prefabricated slat frames 32 is supported upon a scissors elevator 104 which is operated on call by hydraulic power to elevate the stack of frames one frame thickness at a time to bring a new frame to the level of the frame ways 92 and into the operating range of the feed pawls of the indexing mechanism 83 after the preceding frame has advanced sufficiently to clear the leading edge of the stack.
- the stack elevator 104 is operated automatically by control means yet to be described.
- the frame ways 92 extend from the magazine 103 to the stapling station, being supported at their rearward ends, adjacent the feed stack, by an upright frame comprising a pair of side columns 106 connected at their upper ends by upper cross beams 107 and 108, and a lower cross beam 109.
- Upper cross beam 108 and lower cross beam 109 are connected by numerous vertical filler rails (not shown) which constitute an abutment against which to emplace the stack 103 of slat frames, whose side edges are guided by posts 110 on the frame elevator 104. They also support the control box 111.
- the entering ends of the frame ways 92 are supported on a slide shaft 1 12 secured in brackets near the upper ends of the columns 106, the connections of each way to the shaft 112 being made by a bracket (not shown) that is secured to the way and adjustably locked in place on the slide shaft 112 by a set screw.
- the frame ways 92 extend forwardly to the front edge of the stapling mechanism support standards 50 from which point the inverted slat frame, after having received its coils, is transferred to extension ways (FIG. 8a only) from which to be re moved in any convenient manner for future operations.
- the indexing mechanism 83 is the most complicated part of the apparatus and is shown in FIGS. 3, 4., the several FIGS. 6, and also in both FIGS. 8.
- It consists essentially of double-acting double-ended air cylinder 114 whose reciprocable piston rod 116 is suitably extended and fitted with three depending feed dogs or pawls 118, 120 and 122, of which the pawl 118 is normally inoperative, being called into operation only once for each frame to eject the frame from the apparatus upon the completion of the stapling of a row of coils on the last cross slat 33 of the frame.
- the drive cylinder 114 is mounted on the back side of cross beam 44 of the stapling mechanism, i.e., on the exiting side of the stapling station.
- a bracket 124 from which the intermediate feed pawl 120 is suspended, and which also serves as a coupling for an extension rod 126 at the extreme rearward end of which there is similarly mounted a corresponding bracket 128 from which the rearward feed pawl 122 is suspended.
- the extension rod 126 is supported in a slide bearing 107(a) in the upper cross beam 107.
- valve controlling the operation of the drive cylinder 114 is energized by the automatic controller, causing the piston rod 116 to be extended to its retracted position shown in FIG. 3, and then almost immediately, as in a continuous operation, to move forwardly causing the intermediate feed pawl 120 to engage a cross slat of the slat frame then on the ways, and to move that cross slat forwardly to the stapling station.
- the rearward feed pawl 122 either assists in that feeding action during the time when both pawls are operative upon a single frame, or at times causes the rearward feed pawl 122 to engage a cross slat of the next frame of the magazine 1133 to move it onto the frame ways 92.
- the intermediate and rearward feed pawls 120 and 122 are simply bars pivoted on a horizontal axis in their respective mounting brackets, chamfered at their front edges to match the generally vertical rearward edges of the cross slats of the slat frame 32, and urged by gravity to the operative position at which they are stopped by the engagement of their rearward ends with an abutting surface of their mounting brackets.
- the feed pawls 124D and 122 ride freely over the next rearward cross slat of the frame, falling into position poised for the next feed movement (See dotted line position FIG. 60).
- FIG. 6a That portion of the indexing mechanism which serves to position the cross slat accurately for the receipt of a row of coils is shown in detail in the several FIGS. 6.
- the leading cross slat 30 of the frame which is wider than all of the intermediate cross slats 31 of the frame, is positioned at the stapling station to receive its row of coils.
- the feed pawl 120 under the driving force of the air cylinder 114, has moved the leading edge of the slat frame firmly against a pair of positioning stops 1311, each adjustably secured to one of two rock shafts 132 journalled in hearings on the upper side of the flange of the cross beam 44.
- the rock shafts 132 are also shown in FHG.
- FIG. 7 which also illustrates the torsion springs 134 by means of which the rock shafts are normally biased to lift the stops 130 out of the frameengaging position (FIG. 6b).
- the rock shafts flank the indexing cylinder 114, and each is rocked by its own separate crank 136 engaged by the cam end of a push rod 138.
- the pair of push rods 138 flank the piston rod 116 of the cylinder 114, and extend through slide bearings in the web of the T-shaped cross girder 44 to bearing blocks 140 secured to sides of a central channel member 142 cantilevered rearwardly from the web of the cross girder 44.
- the push rods 138 are positioned so that their chamfered or cammed front ends are posed to contact the roller of the rock-shaft crank 136 when the feed mechanism is in the retracted position.
- a compression spring 146 surrounding the push rod between the push block 144 and the web of the cross girder 44 (FIG. 6b).
- the push rods 138 are advanced to the position of FIGS. 6a and 6c, the cam ends of the rods turning the cranks 136 to rotate the stop 130 to its depending position at which to intercept the leading edge of the frame 32.
- the push rods 138 are advanced by cross pins 148 extending sidewardly from the bracket 124, which on the fully retracted stroke of the piston rod 116, is positioned well to the rear of the push blocks 144.
- the push blocks 144 are in sliding contact with the sides of the support channel 142 to prevent the turning of the rod 138 on its own axis while it reciprocates (Compare FIG. 4 and 6).
- the frame stops are actuated on every feed stroke of the machine, but as it depends from the rock shaft only sufficiently to engage the upper layer 30a of only the leading cross slat, it is in fact inoperative and of no consequence during the indexing of subsequent cross slats 31 and 33 of the frame.
- the upper frame stop 130 For the second and all succeeding cross slats of an individual base frame, the upper frame stop 130, as earlier indicated, is ineffective, and a second frame stop 150 is therefore provided, insertable through a notch or slot 152 through the supporting flange of the frame ways 92 from the under side thereof at the appropriate time to intercept the forward edge of the second and all succeeding cross slats of the frame.
- FIGS. 6a, 6b and 60 show not only how the lower frame stop 150 serves its function, but also how it is selectively disabled for the passage of the leading cross slat 30 of the slat frame.
- the iower frame stop 150 is shown in operative position in FIG. 6c engaged with the forward edge of the second cross slat 31 which is firmly seated against it by the intermediate feed pawi 120 of the indexing mechanism.
- the lower frame stop is essentially hook-shaped and pivotally mounted on the underside of the frame way 92 to be rocked by a crank 154 into and out of frame-engaging position under the influence of an air cylinder 1S6 mounted on a bracket 157 secured to the way 92.
- the stop-actuating cylinder 156 is singleacting, having a self-contained spring (not shown) which tends to extend the piston rod so as to retract or withdraw the lower frame stop from engaging position.
- the cylinder is operated by a solenoid valve under the influence of a normally open switch 158 which is mounted on the support channel 142 and positioned to be operated by a cam bar 160 on the upper surface of the mounting bracket 124 of the intermediate feed pawl 120.
- a normally open switch 158 which is mounted on the support channel 142 and positioned to be operated by a cam bar 160 on the upper surface of the mounting bracket 124 of the intermediate feed pawl 120.
- a second and normally closed switch 162 is mounted on the upper side of the flange of the cross girder 44 with its operator positioned to be intercepted by the upper portion 30a of the leading cross slat of the frame. That switch is in series with the normally open switch 1S8.*When that switch is operated as indicated in FIG. 6a, the switch 162 is opened, rendering it impossible to close the control circuit to the valve controlling the lower frame stop Therefore, as long as the switch 162 indicates the presence of the leading cross slat 30, the lower frame stops 150 remain inoperative, and the leading edge of the frame advances to the upper stop 130.
- trailing cross slat 33 is the mirror image of the leading slat 30, i.e., with the upper thickness thereof disposed at the right-hand side or trailing edge of the last cross slat, it is not in a position to actuate the switch 162 before the leading edge of the trailing slat contacts the lower stop 150, and therefore is of no effect in disabling the lower frame stop 150 for the interception of the last or trailing cross slat 33 of the frame.
- Both the sensing switches 164 and 166 are of the normally closed type, and are wired in series with the elevator motor starter so that the closing of both is required to call the elevator into operation.
- a circuit is finally completed through both switches, and the stack begins to rise until the rearward switch 166 is once more operated to open the circuit.
- the uppermost frame of the stack is then at the level of the frame ways 92, and on the next indexing movement opens the forward switch 164 as well.
- the spacing of the two sensing switches 164 and 166 controls the spacing between successive slat frames, which is set at a distance slightly in excess of the normal interslat spacing so as to allow for the greater width of the leading slats of the frame.
- the increment of movement is the length of the feed stroke of the indexing mechanism
- the interframe spacing will be the length of the feed stroke or some multiple thereof, determined by the placement of the forward switch 164 along the frame way.
- One feed stroke is sufficient for the purpose, which is in part to permit the intermediate feed pawl to drop into position behind the last or trailing cross slat 33 of the frame so as to thrust it forwardly to the stapling station.
- the electrical control mechanism is arranged for manual operation of each of the functions separately, so that the operator by actuating the necessary switch, can effect one independent indexing movement, advancing the leading slat of the succeeding frame into the stapling station.
- the ejector pawl 118 is a forward extension of the indexing mechanism 83. Together with its controller, it is shown in greater detail in FIG. 8, the pawl 118 also being seen in end view in FIG. 7.
- the forward ejector pawl 118 is normally inoperative, being lifted and maintained out of frame engaging position by a small single-acting air cylinder 170.
- the pawl itself is pivotally suspended from a bracket 172 affixed to the forward end of the piston rod 116, and by its unbalanced weight is urged to the broken line frame engaging position of FIG. 8a.
- a return spring (not shown) which is within and part of the air cylinder 170 which is mounted on the forward face of the pawl bracket 172 and has attached to its downwardly extending piston rod a lifting arm 174 which is pivotally connected to the pawl 118 by a pin-and-slot connection 176 within a recess 1'78 milled in the pawl forwardly? of its main pivotal mounting.
- the ejector pawl 118 When the air cylinder 170 is energized, therefore, the ejector pawl 118 is lifted and maintained in its elevated position, where it remains idle throughout the normal operation of the indexing mechanism, air being constantly supplied to the cylinder 170 except when the last or trailing cross slat 33 of the frame is positioned at the stapling station (and fleetingly and ineffectively during the arrival of the leading cross slat 30 at the stapling station).
- the control of the forward ejector pawl 118 is effected by a small air valve 180 through which pressure air is normally applied to the cylinder 170.
- the valve is mounted on a bracket 182 screwed to the flange of the cross beam 44 and positioned so that its operating leaf 134 will be lifted by the upper layer 33a of the trailing cross slat 33 when the latter is positioned at the stapling station.
- the valve is operated by lifting the operating leaf 184 the connection to the pressure source is interrupted and the cylinder is vented to atmosphere through the valve body.
- the feed pawl 118 is correspondingly depressed to the broken-line, slat-engaging position of FIG.
- the pawl 118 overrides and falls behind one of the intermediate cross slats 31 of the completed frame, and on the forward stroke removes it from the stapling station.
- valve 180 is operated by the passage thereunder of the upper layer 33a of the trailing slat 33, it will be apparent that it is similarly lifted by the upper layer 30a of the leading slat 30, but only momentarily as will be apparent from comparison of FIG. 6a, which illustrates the leading cross slat at the stapling station, with FIG. 8b, which shows the trailing cross slat similarly so positioned.
- FIG. 6a which illustrates the leading cross slat at the stapling station
- FIG. 8b which shows the trailing cross slat similarly so positioned.
- the ejector pawl 118 is momentarily but idly positioned in the broken-line position of FIG. 8a as the intermediate feed pawl 120 moves the leading cross slat 30 into the stapling station.
- a motordriven industrial timer 111 Central to the operation of the circuit is a motordriven industrial timer 111, the elements of which are enclosed within the broken line of FIG. 9. They include a timing shaft driven by a motor 191 which is placed into operation by an initiating manual switch 192 which is preferably a pedal-operated switch at the operators position in front of the stapling station, and a holding switch 194 operated by a cam on the motordriven shaft.
- the holding switch continues to apply power to the driving motor when the initiating manual switch 192 is released, holding the motor in for essentially one revolution of the shaft after which the holding switch 194 opens, de-energizes the motor, and thus determines the length of an operating cycle.
- cam-operated switches 196, 197, and 198 controlling respectively the solenoid valves 200, 201, and 202 which control respectively the air cylinder 76 which elevates the gun carriage, and with it the air cylinder 98 which depresses the backing bars, the latter two being controlled in common by the valve 200, the air cylinder 81 which rocks the trigger bar to fire the guns, and the air cylinder 114 that powers the indexing mechanism 83.
- the cam-operated or timing switches 196, 197 and 198 are each connected to their respective controlled solenoid valves through one of three manually operated threepole switches 203, 204 and 205 the lower contacts of which must be closed to render the automatic controller operative.
- a fourth manually-operated three-pole switch 206 serves essentially to condition the slat frame magazine 103 for automatic operation.
- timing motor 191 is connected to power through the lower set of contacts of each of the aforementioned manually operated three-pole switches 203 to 206, inclusive, requiring that all such contacts be closed before the timing motor may be energized, and also that the circuit to the timing motor is interrupted if any of those contacts should be opened.
- a third set of contacts of each of the four triple-pole switches 203, 204 and 205 operate signal lamps 207, 208, 209 and 210 to indicate that the timer switches 196, 197 and 198, the elevator 104, and the timer motor 191 are conditioned for operation.
- Each of the air cylinders 76, 98, 81 and 114 controlling these four basic movements is a double-acting cylinder and, accordingly, the solenoid valve which controls each is a two-position springreturn valve which normally applies pressure air to one side of the operating piston while venting the other, but reverses that condition when the controlling timer switches 196 to 198 are closed to power the valve solenoids.
- the air cylinders 156 that operate the lower frame stops 150 are of the single acting type, as earlier mentioned, and spring-biased to retract the lower frame stops from their frame engaging positions (FIG. 6b).
- the valve 212 which controls the cylinder 156 is itself controlled by the earlier-mentioned normally closed switch 162 mounted on the upper surface of the cross beam 44. These two switches, as shown in FIG. 9, are connected in series and when closed cause the admission of pressure air to the cylinder 156 to elevate the lower frame stop.
- the normally open 158 switch is closed after the indexing stroke has proceeded sufficiently to permit the preceding cross slat to clear the stapling station, so that the lower stop 150 may resume its position without obstruction.
- the two normally closed switches 164 and 166 which energize the drive motor of the hydraulic lift mechanism 104 of the frame magazine 103, are connected in series to the drive motor through the same set of contacts of the switch 206 that light the signal lamp 210, the switch 206 thus interlocking the elevator 104 with the timer motor 191.
- the removal of one slat frame from the top of the magazine 103 permits the switch 166 to close, and when the trailing edge of that frame has finally cleared the forward switch 164, the elevating motor is energized, lifting the stack 103 until its uppermost frame again opens the rearward switch 166.
- Each of the solenoid valves 200, 201 and 202 may likewise be operated individually by manual switches 216, 217, and 218 respectively, for testing and maintenance.
- the entire control circuit is connected to power through a doubie-pole single throw switch 219, both lines to which are appropriately fused in accordance with conventional practice.
- the apparatus l have found it advantageous to employ the weight of the individual coils as the method of maintaining their orientation with the stapling gun and thus to perform the stapling with the stapling guns pointed upwardly, and with the springs and the slat frames upside down.
- the indexing mechanism by means of which the slat frame is fed to the stapling apparatus one slat at a time is such as to square" the slat at the stapling station to assure that the springs are attached in a line parallel to the slat edges, and, in the case of the intermediate slats, centrally thereof.
- a stapling gun for stapling helical wire coil springs to a base frame in the manufacture of box springs or the like having a muzzle portion long enough for insertion through the spring axially thereof, a sleeve surrounding said muzzle and conforming with sliding clearance to the interior shape of the spring, said sleeve having a conical nose portion to facilitate its entry into the spring and a groove in its end face to position a wire to be straddled by a staple fired by the gun.
- said carriage being movable on said frame to elevate said guns from a lower loading position, at which each gun is poised to receive a spring, to an upper firing position, at which each spring is carried by its gun against the underside of an inverted base frame and stapled thereto,
- backing means engageable with the base frame on its top side in opposition to the guns to buck the same when fired
- indexing means for advancing said base frame incrementally for the stapling thereto of successive rows of springs.
- the indexing mechanism is especially adapted for base frames comprising a plurality of cross slats connected together in spaced relation, and in which the frame is indexed slatby-slat for the stapling of a row of coils to each slat, said indexing means comprising a reciprocable feed pawl freely movable over said slats in the retracting direction but abuttable therewith centrally of the slat on its trailing edge when moved in the advancing direction, and two widely spaced stops engageable with the leading edge of the slat near the ends thereof, said pawl and stops serving to square the slat into alignment with the row of guns on the carriage.
- the indexing mechanism is extended rearwardly and provided with an auxiliary feed pawl operable in unison with said first mentioned feed pawl, an elevator mechanism adapted to support a stack of slat frames and to elevate the same to place the uppermost frame of the stack at the level of the frame ways and in the effective working zone of said auxiliary feed pawl, a pair of sensing switches operated in sequence by said uppermost frame upon reaching said level and subsequently upon advancing along the ways during a subsequent feed stroke of said auxiliary feed pawl, said elevator mechanism being operative to elevate the stack whenever an advancing slat frame clears both switches, the spacing between successive slat frames being controlled by the spacing of said switches.
- the apparatus of claim 3 especially adapted for a base frame comprising a plurality of slats attached to longitudinal side rails and in which the backing means includes a beam overlying the slat frame at the stapling station and having thereon a reciprocable backing bar movable into contact with the underlying frame slat in alignment with said guns in firing position, thereby to absorb the impact of the firing of the guns.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Forests & Forestry (AREA)
- Dovetailed Work, And Nailing Machines And Stapling Machines For Wood (AREA)
Abstract
Description
Claims (7)
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US21884372A | 1972-01-18 | 1972-01-18 |
Publications (1)
Publication Number | Publication Date |
---|---|
US3770180A true US3770180A (en) | 1973-11-06 |
Family
ID=22816724
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US00218843A Expired - Lifetime US3770180A (en) | 1972-01-18 | 1972-01-18 | Apparatus for manufacturing box springs |
Country Status (1)
Country | Link |
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US (1) | US3770180A (en) |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5904789A (en) * | 1997-11-24 | 1999-05-18 | Imaginal Systematics, L.L.C. | Box spring stapler apparatus and method |
US20030098327A1 (en) * | 2001-11-29 | 2003-05-29 | Durkos Larry G. | Box spring stapler apparatus |
US20050251981A1 (en) * | 2004-04-09 | 2005-11-17 | Mossbeck Niels S | Positioning device for staple guns and method of use |
US20060011696A1 (en) * | 2004-04-09 | 2006-01-19 | Mossbeck Niels S | Positioning device for staple guns and method of use |
US20060112366A1 (en) * | 2004-11-20 | 2006-05-25 | Cadence Design Systems, Inc. | Method and system for optimized automated IC package pin routing |
US20060265850A1 (en) * | 2005-05-13 | 2006-11-30 | Rowe Brian A | Automatic box spring fastening apparatus |
US7222402B1 (en) | 2001-11-29 | 2007-05-29 | Imaginal Systematics, Llc | Box spring stapler apparatus |
US7574788B1 (en) | 2004-10-01 | 2009-08-18 | Atlanta Attachment Company | Foundation cover stretching and stapling system |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3084345A (en) * | 1959-11-16 | 1963-04-09 | Jr Frederick G Hodges | Apparatus for making spring units |
US3168745A (en) * | 1962-10-29 | 1965-02-09 | Sterling Mattress Co | Machine for attaching bedsprings to frame |
US3261527A (en) * | 1964-10-07 | 1966-07-19 | Signode Corp | Apparatus for firing a plurality of fastening tools |
-
1972
- 1972-01-18 US US00218843A patent/US3770180A/en not_active Expired - Lifetime
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3084345A (en) * | 1959-11-16 | 1963-04-09 | Jr Frederick G Hodges | Apparatus for making spring units |
US3168745A (en) * | 1962-10-29 | 1965-02-09 | Sterling Mattress Co | Machine for attaching bedsprings to frame |
US3261527A (en) * | 1964-10-07 | 1966-07-19 | Signode Corp | Apparatus for firing a plurality of fastening tools |
Cited By (15)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5904789A (en) * | 1997-11-24 | 1999-05-18 | Imaginal Systematics, L.L.C. | Box spring stapler apparatus and method |
WO1999026766A1 (en) * | 1997-11-24 | 1999-06-03 | Imaginal Systematics L.L.C. | Box spring stapler apparatus and method |
US7222402B1 (en) | 2001-11-29 | 2007-05-29 | Imaginal Systematics, Llc | Box spring stapler apparatus |
US6935546B2 (en) | 2001-11-29 | 2005-08-30 | Imaginal Systematics, Llc | Box spring stapler apparatus |
US20050210647A1 (en) * | 2001-11-29 | 2005-09-29 | Durkos Larry G | Box spring stapler apparatus |
US20030098327A1 (en) * | 2001-11-29 | 2003-05-29 | Durkos Larry G. | Box spring stapler apparatus |
US7467454B2 (en) | 2001-11-29 | 2008-12-23 | Imaginal Systematics, Llc | Box spring stapler apparatus |
US20050251981A1 (en) * | 2004-04-09 | 2005-11-17 | Mossbeck Niels S | Positioning device for staple guns and method of use |
US20060011696A1 (en) * | 2004-04-09 | 2006-01-19 | Mossbeck Niels S | Positioning device for staple guns and method of use |
US7490401B2 (en) | 2004-04-09 | 2009-02-17 | L&P Property Management Company | Positioning device for staple guns and method of use |
US7516533B2 (en) | 2004-04-09 | 2009-04-14 | L&P Property Management Company | Positioning device for staple guns and method of use |
US7574788B1 (en) | 2004-10-01 | 2009-08-18 | Atlanta Attachment Company | Foundation cover stretching and stapling system |
US20060112366A1 (en) * | 2004-11-20 | 2006-05-25 | Cadence Design Systems, Inc. | Method and system for optimized automated IC package pin routing |
US20060265850A1 (en) * | 2005-05-13 | 2006-11-30 | Rowe Brian A | Automatic box spring fastening apparatus |
US7562443B2 (en) | 2005-05-13 | 2009-07-21 | Rowe Brian A | Automatic box spring fastening apparatus |
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