APPARATUS FOR MANUFACTURING COMBINED SPRINGS

Abstract: The apparatus for manufacturing combined springs according to the present invention is provided with a first unit for forming coiled springs (23) sequentially out of a single wire and shaping spring wires (20) obtained by arranging these coiled springs (23) in a lateral row so that side arms (25) of the coiled springs (23) are adjacent to each other, and a second unit extending across the spring wires (20) and adapted to shape spiral wires wound around the side arms (25) of the spring wires (20) so that the spiral wires extend across the side arms (25). The second unit is provided with a spiral wire shaping means, a supply means (251) for supplying spiral wires while measuring and controlling the length of the spiral wires, which are being supplied, in such a manner that this length substantially agrees with the width of the spring wires, and an end forming means (201) which is disposed so that the end forming means can be positioned freely in the widthwise direction of the spring wires, and which is adapted to cut the end portion of a spiral wire which is on the front side thereof with respect to the direction of feeding the spiral wires and projects in the widthwise direction of the spring wires, and then bends the spiral wire.

Description: This invention relates to an apparatus for manufacturing spring units used for mattresses and the like, according to the preamble portion of claim 1. Japanese Utility Model Publication JP-YA-53-35 573 corresponding to GB-A-1,095,980 and representing the nearest prior art discloses an apparatus for manufacturing a spring unit, in which a plurality of coil springs are formed by bending a resilient wire. These coil springs form a spring band having a predetermined thickness, such that coil springs are arranged side by side in a row and their side limbs are adjacent to one another. The spring units further comprise helical wires which interconnect the side limbs of the spring band. These helical wires are wound around the side limbs by moving the helical wires in the axial direction thereof while the helical wires are rotated in a manner of a screw in a direction transverse to the spring band. After the helical wires are wound to the spring band, the ends of the helical wires are cut off and then bent by a tool, in the end treatment. Where the spring bands are used for mattresses, the width of the spring bands varies, depending on the sizes of the mattress, that is, whether the mattress is used for double size, semi-double size or single size bed. Therefore, it is necessary to vary the feeding length of the helical wires in accordance with the width of the spring bands. However, in the prior apparatuses for manufacturing spring units, the feeding length of the helical wire is not automatically controlled in accordance with the width of the spring bands. Further, the opposite ends of the helical wires wound around the spring bands are cut off and bent by the tool, in the end treatment. The tool is, however provided in a fixed position in relation to the width direction of the spring bands. Therefore, when the width of the spring bands is changed from that for the double size to that for the semi-double or single size, the position of the tool is deviated from the lateral borders of the spring bands in the width direction thereof, so that the ends of the helical wires are no longer treated by the tool. EP-A1-248661 describes an apparatus for use in making spring units. For manufacturing said spring units, for example mattresses or the like, a helical wire is screwed in the arrangement of spring elements from one side of said arrangement. A carriage supports one side portion of a trimming and bending device. The carriage only serves as holding or mounting means of a part of said combined trimming and bending device but is not a part of an end treatment device. US-A-2,898,950 refers to a spring assembly machine. Adjacent spring elements can be connected by a helical wire which is screwed in said spring elements. The width of the band of spring elements, forming the mattress, is not adjustable. The wire, which is fed as a straight wire, is, in a subsequent manufacturing step, formed into a helical form. Further, the prior art apparatus for making spring unit as disclosed in the publication, is not provided with any means for forming straight wires into helical form and automatically feeding these helical wires to the side limbs of the spring bands. Therefore, it is necessary to perform, as independent steps, a step of forming helical wires and a step of combining these helical wires with the spring bands, thus causing the productivity of the spring units to reduce. It is an object of the present invention to provide an apparatus for manufacturing a spring unit being simple in construction and fail-safe in operation and providing the possibility to control the feeding length of helical wires in accordance with the respective width of spring bands and which allows an end treatment of the helical wires to be performed even if the width of the spring bands is changed, and, furthermore, automatically and continuously performs a step of forming straight wires to a helical form and a step of winding the helical wires around the side limbs of the spring bands. According to the invention, the object is solved by the features of the main claim. The subclaim shows further positive developments of the present invention. A further first object of the invention is to provide an apparatus for manufacturing spring unit, which controls the feeding length of helical wires in accordance with the width of spring bands and allows end treatment of the helical wires to be performed even if the width of the spring bands is changed. A further second object of the invention is to provide an apparatus for manufacturing spring unit, which can automatically and continuously perform a step of forming straight wires to a helical form and a step of winding the helical wires around the side limbs of the spring bands. To attain the further first object of the invention, there is provided an apparatus for manufacturing spring unit, which comprises a feeding device for feeding helical wire while the feeding device controls a feeding length of helical wire so as to be substantially equal to the width of the spring band, and an end treatment device provided such that its position is adjustable in the width direction of the spring bands, for cutting off and bending the forward end of the helical wire in the feed direction thereof at a position where one of the lateral borders of the spring bands is located. With the feeding device and the end treatment device, it is possible to control the feeding length of the helical wire in accordance with the width of the spring band, cut off and bent the forward end of the helical wire in the feeding direction. Consequently, even if the width of the spring bands is changed to that for the double size, semi-double size or single size, it is possible to correspondingly feed a proper length of helical wire and also reliably treat the forward end of the helical wire. To attain the further second object of the invention, there is provided an apparatus for manufacturing spring unit, which comprises a forming device including a feeding mechanism for feeding straight wire prior to a step of interconnecting the side limbs of the spring bands with helical wire, a forming mechanism for forming the straight wire fed from the feeding mechanism into a helical form and an adjustment mechanism for adjusting the pitch of the helix formed in the forming mechanism. Where such a forming unit is provided in the apparatus for manufacturing spring unit, the step of forming helical wire and step of combining the helical wire with the spring bands can be performed continuously and automatically, thus permitting the improvement of productivity. The pitch of the helical wire can also be adjusted by the adjustment mechanism, so that it is possible to eliminate the dispersion of the pitch due to the material of the wire and permit reliable interconnection of the side limbs of the spring band. Fig. 1 is a plan view showing a spring unit according to the present invention; Fig. 2 is a side view showing the spring unit shown in Fig. 1; Fig. 3 is a perspective view showing one of spring elements constituting the spring unit shown in Figs. 1 and 2; Fig. 4 is a side view showing an apparatus for manufacturing spring units according to the present invention; Fig. 5 is a fragmentary view, to an enlarged scale, showing a portion of the apparatus shown in Fig. 4 other than removed portion; Fig. 6 is a perspective view showing a portion of the apparatus shown in Fig. 4 other than a removed portion; Fig. 7 is a sectional view, to an enlarged scale, showing the portion of apparatus shown in Fig. 4; Fig. 8 is a perspective view showing a portion of mechanism shown in Fig. 6 other than a removed portion; Figs. 9a to 9c are fragmentary side views showing sequential three steps in the process of manufacturing a spring unit with the apparatus shown in Fig. 4; Fig. 10 is an end view showing a spring band shown in Fig. 3 along with a modified guide; Fig. 11 is an elevational view showing the entire apparatus; Fig. 12 is an elevational view showing an end treatment device shown in Fig. 2; Fig. 13 is a side view showing the end treatment device; Fig. 14 is a perspective view showing the end treatment device; Fig. 15 is a sectional view showing a slider; Fig. 16 is a plan view showing a bend removal section; Fig. 17 is a sectional view showing a feeding mechanism; Fig. 18 is a sectional view showing a forming mechanism and an adjustment mechanism; and Fig. 19 is a side view showing the adjustment mechanism and an adjuster. Figs. 1 and 2 schematically illustrate spring unit manufactured by the apparatus according to the present invention. This spring unit is intended for use in a spring mattresses, but similar units may well be used for other upholstery, cushions, motor vehicle seats and the like. The spring unit illustrated comprises a plurality of bands of springs 20. Each band 20 has a shape as shown in Fig. 3, as will be described later in detail. Bands 20 are arranged side by side in rows and are interconnected by helical wires 21 and 22 extending transversely of the bands. As shown in Fig. 2, two sets of helical wires are used. One set of the helical wires are designated by reference numeral 21 and are used for the upper face of the spring unit. The other set of the helical wires are designated by numeral 22 and are used for the lower face of the spring unit. The helical wires in these two sets are provided at the top and bottom of the spring unit respectively and are staggered relative to one another so that they occur alternately. Each band 20 comprises a length of resilient wire bent so as to form a plurality of coils or coil springs 23 arranged side by side in a row. The coil springs are generally helical in shape and successive springs are alternately left- and right-banded. Each coil spring 23 is joined at one end to the adjacent coil spring to one side of it and at the other end to the adjacent coil spring to the other side of it. Each pair of adjacent coil springs 23 is interconnected by loop 24 which consists of part of the length of wire constituting the pair of coil springs 23. Loop 24 is shaped approximately as three sides of a rectangle or as the letter U, having two generally parallel side limbs 25 and a connector 26 between side limbs 25. Loop 24 is substantially flat and lies in the plane of one edge face of band 20. Side limbs 25 extend in a direction transverse to the length of the band. Connector 26 extends lengthwise of the band. The length of connector 26 is such that side limbs 25 to which it is joined are so spaced that two springs 23 to which they are joined stand between side limbs 25. Loops 24 are successively arranged along the opposite edge faces of band 20 so that there are two groups of loops 24. More specifically, one group of loops 24 is arranged along one edge face of band 20. The other group of loops 24 are arranged along the other edge face of band 20. There is little or no gap between successive loops 24 in each group. Therefore, considering any pair of successive loops 24 in either group, e.g., coil springs 27 and 28, are isolated. It will be understood that one side limb 29 of one coil spring 27 is located close to and parallel with one side limb 30 of other coil spring 28. As shown in Fig. 1, helical wires 21 and 22 embrace a pair of adjacent side limbs 25 of each band 20, that is, a pair of adjacent side limbs 25 is embraced by one helical wire. Each coil spring 23 in each band is coupled to the two coil springs on either side of it such that each coil spring 23 has some of its turns linked to turns of the two adjacent coil springs. This relation of coupling is shown in Fig. 3 (although it is not shown in Fig. 1 for the sake of simplicity of the drawings). In end view, each band 20 presents a sinuous appearance; and at no point between one edge and the other edge has band 20 a thickness much greater than the thickness of the wire from which band 20 is formed. Fig. 10 shows an end view of one band 31. The band having this shape can therefore be wound into a drum-shaped coil so that the drum-shaped coil has substantially parallel with the longitudinal axes of the bands and turns of the drum-shaped coil intersects turns of the adjacent coil. Figs. 4 to 8 show an apparatus which is intended for use to manufacture a spring unit using a plurality of bands which comprise the coils wound in such a shape. Bands wound into a ring form are laid on suitable supports (only a single support being shown in Fig. 4). The support is provided with base 32. Base 32 has an upright pillar-like member. A plurality of sleeves 33 are mounted on the pillar-like member. Each sleeve 33 has arm 34 extending transversely. Only a single sleeve with arm 34 is shown in Fig. 4 for the sake of simplicity of the drawings. Upright spindle 35 is mounted on the free end of each arm 34. Spindle 35 supports a rotor. The rotor comprises pipe-like member 36 rotatable about spindle 35 and circular plate 37 mounted on pipe-like member 36. Spring band which is wholly designated by reference numeral 38, rests on circular plate 37. Fin 39 is provided on an upper end portion of pipe-like member 36. Fin 39 engages with a central portion of the spring band. The rotor thus rotates with spring band 38. Adjustable friction pad 40 is provided to hold a lower end portion of plate-like member 36 to prevent spring band 38 unwinding in an uncontrolled manner. It will be understood that this apparatus of manufacture permits a desired number of spring bands to be mounted for assembly to obtain a complete spring unit. A main portion of the apparatus according to the present invention is shown in Fig. 4. The main portion includes support 42. Frame 43 is secured to support 42. Frame 43 is provided with a plurality of guide grooves 44 arranged transversely in a row. Frame 43 includes flat bottom plate 45 (Fig. 5) having upright plates 46. Upright plates 46 are parallel to and spaced apart from one another. Guide passages are defined between adjacent upright plates 46. Each guide groove 44 has outwardly open rear end as designated by reference numeral 47. Upright plates 46 extend vertically so that the spring band can be readily guided from the support into the apparatus. Although not shown in detail, in a modification of the apparatus a plurality of bars are provided in lieu of guide grooves 44. Each spring band is guided by three or more parallel bars which are spaced apart from one another. In this modification, bars are positioned on the opposite sides of the spring band and arranged in grooves which are defined by the curved spring band and extend in the longitudinal direction. This arrangement is apparent when the spring band is viewed from its one end. A typical arrangement of bars, in which three bars 48 are used, is shown in Fig. 10. The end portions of guide grooves 44 remote from the band reception end thereof, extend straight, horizontal and parallel and is leading to a linking station which will be described later in detail. Feeding means are provided which serve to engage some of the spring bands and to push them bodily forwards, in each cycle of operations of the apparatus. The feeding means include four parallel links 49 and 50, two provided on each side of the apparatus. These links are rotatably supported at their lower end by support 42 and coupled, at a point above their lower end, to a pair of adjustable connecting links 51. Connecting links 51 can be reciprocally moved by piston-and-cylinder assembly 52 operable by compressed air. Assembly 52 is mounted on stationary frame 43 and coupled to arm 53 mounted on shaft 54. Shaft 54 supports arms 55 at its opposite end portions. These arms 55 are coupled to pair links 50 positioned at rear side. Transporter 56 of wheel type can run along stationary frame 43. Transporter 56 has a pair of parallel bars 57 extending across the open tops of guide grooves 44. Transporter 56 is coupled to and reciprocally moved by pair links 50 which are arranged at rear side. Bars 57 each support a plurality of fingers 58 (Fig. 7). These fingers 58 are hung from bars 57 into guide grooves 44. As shown in Fig. 7, each finger 58 can swing forwards and can not swing backwards. In each operation cycle of piston-and-cylinder assembly 52, fingers 58 engage the spring bands and pushes them forwards by a distance corresponding to the width of two coils and then return and can engage the spring bands again at a position thereof spaced apart a distance corresponding to the width of two coils from the position, at which fingers 58 have engaged the spring bands (Fig. 7). Transversal bar 59 extends between pair links 49 arranged at forward side and carries a plurality of pawls 60. Of these pawls 60, each pair is associated with each spring band. One of the pair pawls is positioned upwardly of the spring band and the other is positioned downwardly of the spring band. Pawls 60 have an identical shape as typically shown in Fig. 6. As shown in Fig. 6, pawl 60 has front side portion 61, which can engage one spring band and pull the spring band forwards as the pawl itself is moved forwards, and a rear side portion 62, which is inclined as the rear side portion 62 goes away from the associated spring band. Thus, as the pawl is moved backwards, it is disengaged from the associated spring band. Fingers 58 are arranged so as to push the spring bands forwards by a distance corresponding to the width of two coils in one cycle of operations of the apparatus. At the linking station, there are two sets of jaws 63 and 64 which constitute grasping means. One set of jaws 63 are arranged below the spring bands and the other set of jaws 64 are arranged above the spring bands. Upper and lower jaws 64 and 63 are vertically spaced apart by a distance substantially corresponding to the thickness of coil springs 23 and also spaced apart horizontally by a distance substantially corresponding to the diameter of coil springs 23. Each set of jaws comprises pairs of jaws corresponding in number to the number of spring bands. Each pair of jaws act on the associated spring band. One jaw 65 of each pair is stationary and extends in a generally vertical direction, as shown in detail in Fig. 6. The other jaw, i.e., jaw 66, is pivotably connected to fixed jaw 65 in a considerably large angle range, by horizontal pivotal pin 67 which extends transverse to the direction of feeding of spring bands. Although only one lower jaw set 63 is shown in Fig. 6, the remaining lower jaw set is the same as the illustrated one. The upper jaw sets are also alike the lower ones except for that they are inverted. Each jaw pair is controlled for operation by associated piston-and-cylinder assembly 68 operable by compressed air. The cylinder of assembly 68 has is pivotally connected to frame 43 and its piston is coupled so that extension 69 of jaw 66 extending beyond pivotal pin 67 is pivotably. Inclined plate 41 is mounted on the rear end of stationary jaw 65 of each lower jaw set 63 so that the edges of the spring band can move on the jaws without the edges of the spring band being caught by the jaws (Fig. 5). When the apparatus described above, the pairs of jaws in the upper and lower jaw sets 64 and 63 are opened, and the feeding means is operated to feed the spring bands forwards as described above. When the forward movement of the spring bands is completed, the pairs of side limbs 25 of the loops have passed over the backs of stationary jaws 65 and then snapped into the open mouths of the jaws. While some pairs of side limbs 25 are urged against the inner faces of the adjacent stationary jaws 65, almost side limbs 25 move a short distance beyond the stationary jaws but remain in the open mouths of the jaws. Next, movable jaws 66 are then pivoted backward against the feeding direction of the spring bands, toward stationary jaws 65. Movable jaws 66 carry the pairs of side limbs 25 backwards to stationary jaws 65 and accurately position the side limbs. The distance covered by side limbs 25 are so small that the spring bands are not moved bodily but are only flexed somewhat by the movement of the side limbs. In Fig. 6, jaw 66 which has pivoted is shown at its intermediate position between its perfectly open position and perfectly closed position. The cycle of operations described above is illustrated in Fig. 9. Fig. 9a shows a state, in which the jaws are open and the spring bands have moved forwards by fingers 58. Fig. 9b shows a state, in which fingers 58 are in the foremost positions and the pairs of side limbs 25 are in the jaws. Fig. 9c shows a state, in which the jaws are closed and side limbs 25 are pulled slightly rear-wardly, and also a state, in which the fingers are returned to the rear-most positions to be ready for pushing the bands forwards if the jaws are opened. Recess indicated by reference numeral 70 is defined in the inner faces of each pair of jaws 65 and 66, that is, the faces which meet when the jaws are closed, as shown in Fig. 6. Recess 70 forms a tubular opening having two open ends for receiving a pair of side limbs 25 of the spring band. Further, the wall defining the tubular opening has some grooves as indicated by reference numeral 71. These grooves serve to define a continuous helix when the jaws are closed. A slight gap remains between the jaws of each pair so that a portion of helical wire 21 successively linked to side limbs 25 can be received into the gap. Such helical groove receives one helical wire 21 for connecting the side limbs of one pair as shown in Figs. 1 and 2 and hence linking together adjacent spring bands. Helical wire 21 is introduced, in a manner of a screw, into the helical from one end of the jaws of each pair immediately after the jaws are closed. Each of the two helical wires is rotated and moved axially by the mechanism as shown in Fig. 6. This mechanism is mounted on stationary frame 43 such that the mechanism faces the device shown in Fig. 4. The mechanism comprises a pair of parallel rollers 72 having respective annular grooves. Rollers 72 can be continuously rotated in the same direction by a motor (not shown). Third roller 73 also having annular grooves is mounted in support means 74, which is pivotally coupled to frame 43 at a position shown by reference numeral 75. Manual lever 76, which is pivotally connected to frame 43 at the lower end portion thereof, supports arms 77. These arms 77 center a slot provided in support means 74 as shown. Lever 76 is urged to the illustrated position by coil spring 78 and is controlled by adjustable stopper 79. When using this lever 76, lever 76 is pulled downwards by the operator of the apparatus and released after inserting one end of one helical wire 21 between rollers 72 and 73. In consequence, the helical wire is pulled in the length direction while it is rotated, in the condition that the helical wire is held between the rollers. The distance covered by the helical wire is restricted by a stopper which is secured to the apparatus on the side opposite to the feeding mechanism described above. After two helical wires 21 have been linked to the spring bands, the end portions of the spring bands, which project a short way beyond the sets of jaws, are cut off. The newly formed ends of helical wires 21, close to the jaws which is positioned at the end side, are bent inwards. The newly formed ends is thus wound around the adjacent portion of the spring band which is positioned at end side. As a result, the loop 24 is formed. This cutting and bending of the end of each helical wire 21 is performed by fixed tool 80 (Figs. 6, 8 and 11). Tool 80 constitutes a first end treatment device which is pivotably connected to stationary member 81 at the adjacent end of of the jaw pair by flat pin 82 extending parallel with the feeding direction of the spring bands. The first end treatment device, as shown in Fig. 11, comprises pairs of tools 80, each pair is vertically spaced apart from one another by the same distance as the thickness of spring bands 38. The pairs of tool 80 also are spaced apart a predetermined distance in the feeding direction of helical wire 21. More specifically, the vertical set of rearward tools 80 which is positioned at the inlet of helical wire 21 in the feeding direction and the pair of forward tools 80 at a forward position are spaced apart from one another by a distance substantially equal to the width of a double size bed using spring band 38. In Fig. 6, tool 80 is shown separated from the adjacent jaw shown in Fig. 8. Stationary cutter block 83 shown in Fig. 8 is bonded to stationary member 81. Helical wire 84 is also shown in Fig. 8. In use, tool 80 is pivoted in the direction of arrow by a piston-and-cylinder assembly operable by compressed air, piston 85 of which (Fig. 6) is coupled to extension 86 of tool 80 beyond pivot pin 82. Upright lug 87 urges helical wire 84 against cutter block 83 to cut off the end of the helical wire and bend the cut end toward the adjacent band until the cut end forms a closed or substantially closed loop. After the cutting and bending, tools 80 are returned to their initial positions, the jaws are opened to release the helical wires, and the feeding means is again operated to move the bands and completed part of the spring unit forwards. Links 49 are pivoted about their lower ends, so that pawls 60 are raised as they pulls the linked bands forwards, thus raising the bands. Thus, the bands are made to be readily separable from the lower sets of jaws 63. The separation of the bands from the jaws is assisted by transverse bars 88 which are disposed below the bands and secured to links 49 through brackets 89. The upward movement of the bands tends to obstruct rather than assist the passing of the bands over the upper sets of jaws 64. To overcome this difficulty, stationary bar 90 which extends parallel to transverse bars 88 is mounted above the bands between the jaws and links 49. When bands 38 are for a semi-double size or single size bed, the forward end of helical wire 21 in the feeding direction can not be cut off and bent by the forward-side tools 80 of the first end treatment device. In such a case, the treatment is performed by second end treatment device 201 disposed in the feeding direction of bands 38, as shown in Fig. 4. Second treatment device 201 has support 202. Guide rail 203 is provided on support 202 such that guide rail 203 extends horizontally in the width direction of bands 38, as shown in Figs. 12 to 15. Slider 204 is slidably mounted on guide rail 203. Slider 204, as shown in Fig. 15, comprises bottom plate 205, opposite side plates 206 and top plate 207, these plates surrounding the outer periphery of guide rail 203. When screws 208 securing top plate 207 to side plates 206 are loosened, slider 204 can be moved along guide rail 203. Two upper and lower sets of jaws 211 and 212 are arranged on slider 204 via mounting member 209. Jaws 211 and 212 have the same structure as jaws 63 and 64 provided in the main part of the apparatus. More specifically, as shown in Fig. 14, jaw 213 is fixed, while jaw 214 is pivotable about pin 215. Jaw 214 can be driven by first piston-and-cylinder assemblies 215, respectively. Further, mounting member 209 is provided with a pair of, i.e., upper and lower movable tools 216 having the same structure as tools 80 as shown in Fig. 8. Each movable tool 216 is pivoted by pin 218 to stationary member 217, to which cutter block 219 is secured. Further, each movable tool 216 of the pair is moved in the direction of arrow by second piston-and-cylinder assemblies 221. When movable tools 216 are driven, like the case of Fig. 8 helical wire 84 is urged against cutter block 219 and its end is cut off, and then the cut end is bent toward the adjacent band until the cut end forms a closed or substantially closed loop. When the size of bands 38 is changed from that for the double size to that for the semi-double size or single size, slider 204 is moved in accordance with the change in the width of bands 38 to a position, at which movable tools 216 face the forward edge face of bands 38 in the width direction thereof. The end of helical wire 84 thus is cut off and bent at the forward end face of bands 38 in the width direction thereof. In this operation, first piston-and-cylinder assembly 215 is operated to close upper and lower jaws 211 and 212 and then helical wire 84 is hold by jaws 211 and 212. Next, second piston-and-cylinder assembly 221 is operated to drive movable tools 216 and then the end of helical wire is cut off and bent. Thereafter, first piston-and-cylinder assembly 215 is operated to open upper and lower jaws 211 and 212 so as to release helical wire 84. As a result, third piston-and-cylinder assembly 221 provided on support 202 is operated to rotate feed rod 222 about the lower end thereof in the direction of arrow in Fig. 4. Consequently, feed pawl 223 provided on the upper end of feed rod 222 engages bands 38 and feeds them to the next stage. Second end treatment device 201 is synchronized to the first end treatment device noted above. Reference numeral 224 in Figs. 12 to 14 designates a pair of guide members vertically spaced apart by a distance slightly greater than the thickness of bands 38. These guide members 224 guide the forward end face of bands 38 in the width direction thereof. The various processes described above can be started intermittently by the operator of the apparatus, and the operator can check the results of previous operations prior to the start of the next process. Alternatively, it is possible to permit some or all of the processes described above to be started automatically at the end of a previous process. The feeding means noted above comprises fingers 58 and pawls 60 to engage the bands. If it is found that the apparatus can be operated satisfactorily by omitting some of these parts, the feeding means may be formed by omitting such parts. Straight wires 21a and 22a are reformed by reforming device 101 and fed into between rollers 72 and 73 shown in Fig. 6. Reforming device 101 comprises feeding mechanism 102 and forming mechanism 103. Feeding mechanism 102 includes a pair of bend removal sections 104 having a pair of upper and lower roller groups disposed for removing bends of straight wires 21a and 22a, a pair of strain removal sections 105 for removing strain of straight wires 21a and 22a which have passed through bend removal sections 104, and drive section 106 for feeding straight wires 21a and 22a which have passed through bend removal sections 104 and strain removal sections 105 to forming mechanism 103. As shown in Fig. 16, encoder 251 is coupled via gear train 252 to one roller 250 in the roller groups of bend removal section 104 and converts the rotation numbers of roller 250 into an electric signal. The electric signal is supplied to a counter (not shown) in which the rotational number are counted. The amount of feed of straight wires 21a and 22a is calculated by the rotation number of roller 250. Therefore, once a count of the counter is preset, the feeding of straight wires 21a and 22a is stopped when a predetermined length of wires 21a and 22a has been fed. In this way, helical wires 21 and 22 can be fed in corresponding to the length of the spring unit that depends on whether the spring unit is for single size, semi-double size or double size. It is to be understood that encoder 251 and roller 250 constitute feeding means for measuring and controlling the length of straight wires 21a and 22a to be supplied. Drive section 106 includes housing 107 as shown in Fig. 17. First shaft 108, second shaft 109 and third shaft 111 are rotatably mounted one above another in the mentioned order between parallel and spaced-apart side plates of housing 107 facing each other. Housing 107 is provided with first motor 112 disposed in an upper portion and second motor 113 disposed in a lower portion. First sprocket 114 is fitted on the output shaft of first motor 112, and first chain 116 is passed round first sprocket 114 and second sprocket 115 fitted on one end of first shaft 108. First gear 112a is fitted on one end of first shaft 108 and is meshed with second gear 113 fitted on one end of second shaft 109. First and second rollers 117 and 118 in rolling contact with each other are fitted on the other ends of respective first and second shafts 108 and 109. The outer peripheries of feed rollers 117 and 118 have grooves 119, into which straight wire 21a is introduced. Therefore, when first motor 112 is operated, first and second shafts 108 and 109 are rotated in opposite directions to feed straight wire 21a clamped between pair feed rollers 117 and 118. Third gear 121 and third feed roller 122 are rotatably mounted on the other end of second shaft 109. Gear 121 and feed roller 122 are integrally coupled together. Third sprocket 123 is fitted on the output shaft of second motor 113. Second chain 125 is passed round third sprocket 123 and fourth sprocket 124 fitted on one end of third shaft 111. Fourth gear 126 meshing with third gear 121 and fourth feed roller 127 in rolling contact with third feed roller 122 are fitted on the other end of third shaft 111. Third feed roller 122 and fourth roller 127 have grooves 128 formed in the outer peripheries. Other helical wire 22a can be introduced into the grooves 128. Therefore, when third shaft 121 is driven by second motor 113, third and fourth rollers 122 and 127 are rotated in opposite directions by the meshing of third and fourth gears 121 and 126 irrespective of the rotational state of second shaft 109. Thus, other straight wire 22a introduced into between feed rollers 122 and 127 is fed in the same direction as straight wire 21a. Pair straight wires 21a and 22a fed by feeding mechanism 102, which has the structure as described above, are each fed to forming mechanism 103. Forming mechanism 103, as shown in Fig. 18, has guides 131. Each guide 131 has tapered end 132. Tapered ends 132 are disposed such that they faces outlets of feeding mechanism 102, from which pair straight wires 21a and 22a are fed out. Each guide 132 has coaxial small and large diameter bores 133 and 134 extending axially and communicating with each other. Small hole 133 has an inner diameter slightly greater than the diameter of straight wires 21a and 22a. Forming rod 135 is inserted into large diameter bore 134 from one end thereof and secured in position by screw 136. Forming rod 135 has one end portion formed with straight groove 137 communicating with small hole 133 of guide 132 and the other end portion formed with helical groove 138 having one end communicating with straight groove 137. Collar 139 is rotatably mounted on the other end portion of rod 135 formed with helical groove 138. Detachment of collar 139 from forming rod 135 is prevented by guide cylinder 142 having opposite end flanges 141 and having the same diameter as collar 135. Guide cylinder 142 is secured to reforming device 101. Thus, straight wires 21a and 22a fed to guide 131 of reforming mechanism 103 are formed into helical wires 21 and 22 noted above as they pass through helical groove 138 of forming rod 135. Helical wires 21 and 22 are fed into adjustment mechanism 143. Adjustment mechanism 143 has base which is securedly provided on reforming device 101 as shown in Fig. 18. Base 144 has slide groove 145 extending in the feeding direction of helical wires 21 and 22. In slide groove 145, adjuster 146 is provided which is slidable and capable of being secured in a given position by set screw 147 as shown in Fig. 19. Further, base 144 is provided with adjustment screw 148 for adjusting the position of adjuster 146. Adjuster 146 has mounting hole 149 extending in the thickness direction. Pitch shaft 152 with helical groove 151 at the same pitch as helical wires 21 and 22 is inserted in mounting hole 149 and secured by set screw 153. Helical wires 21 and 22 are formed by forming mechanism 103 and pass helical groove 151 of pitch shaft 152. Thus, by changing the position of helical groove 151 in the direction of arrow due to displacing pitch shaft 152 in the direction of arrow shown in Fig. 18, the pitch of helical wires 21 and 22 is changed as the wires pass through the helical groove. Helical wires 21 and 22 formed by forming mechanism have a pitch which is varied slightly depending on the material of the wire or other factors, and the pitch is therefore adjusted by pitch adjustment mechanism 143. Helical wires 21 and 22 with the pitch thereof having been adjusted by pitch adjustment mechanism 143 are passed through cylindrical guide 153 to be fed into between rollers 72 and 73 as shown in Fig. 6. Roller 72, as shown in Fig. 11, is rotated by endless belt 155 driven by motor 154. Helical wires 21 and 22 that have been supplied into between pair rollers 72 and 73 disposed one above another are fed to side limbs 25 of bands 20 as they are rotated with the rollers with rotation of roller 72. Thus, helical wires 21 and 22 link side limbs 25 of bands 38. First and second motors 112 and 113 are stopped by a signal from the counter connected to encoder 251. When straight wires 21a and 22a are fed to an amount of a predetermined length in accordance with the width of bands 38, first and second motors 112 and 113 are stopped so that wires 21a and 22a will no longer be fed. The apparatus for manufacturing spring unit according to the invention is very useful for readily manufacturing mattresses having different sizes and can also improve the mattress productivity.

Claims: An apparatus for manufacturing a spring unit, in which coil springs (23) are formed by bending a resilient wire, said coil springs (23) being arranged side by side in a row such that side limbs (25) of each of the coil springs (23) are adjacent to one another, said coil springs also forming a band of springs (20) which band has a predetermined thickness, and in which helical wires (21, 22) are wound around the side limbs (25) of each of the coil springs (23) by moving the helical wires (21, 22) in an axial direction while the helical wires are rotated in a manner of a screw in a direction transverse to the band of springs (20), whereby the helical wires (21, 22) interconnect the side limbs (25) of each of the coil springs (23) in a jaw set (63, 64) attached in line to the apparatus, characterized in that the apparatus comprises: feeding means (102) for feeding the resilient wire (21a, 22a) such that the helical wires (21, 22) are moved by a distance corresponding to a width of the band of springs (20); forming means (103) for forming helical wires by working the resilient wire (21a, 22a) fed by the feeding device; first end-treatment-means (80), located on both sides of the jaw set (63, 64), for cutting forward and rear ends of the helical wires (21, 22) and then bending the cut ends of the helical wires; and second end-treatment-means (201) including a slider (204) slidable in an width direction of the band of springs, said slider (204) having: tools (216) for cutting off those portions of the forward ends of the helical wires which are projected from one side of the band of springs and then bending the cut ends of the helical wires; a guide member (224) for guiding one side of the band of springs when the band of springs is fed in a direction perpendicular to the width direction of the band of springs; and jaw members (211, 212) for holding sides of the helical wires when the forward ends of the helical wires are being worked with the tools. An apparatus for manufacturing the spring unit according to claim 1, characterized in that the apparatus comprises an adjustment mechanism (143) for adjusting the pitch of the helical wire (21, 22) formed in the forming mechanism (103).

Inventors: HARA KAZUO, NOMURA TOMOAKI, SASAKI NOBORU, USUI TOSHIO, YOSHINO ISAMU, HARA, KAZUO, NOMURA, TOMOAKI, SASAKI, NOBORU, USUI, TOSHIO, YOSHINO, ISAMU
Applicants: FRANCE BED CO, FRANCE BED COMPANY, LIMITED
Application year: 1988
Main classification: B21F27
IPC codes: B21F3, B21F33, B21F27, B21F35