全自动化弹簧床垫的生产工序有哪些呢？

多功能机器人床垫复合|铁马自动化

◆ 上床网机器人

◆ 柔性抓手

◆ 面料、海绵、床网、棕板等上料机器人

◆ 复合机器人

◆ 海绵包内胆机器生产产线

多项智造优点

◆ 自动上料

床网、顶/底层面料及海绵等填充层由AGV送到指定位置,系统自动完成拆分、上料。

◆ 视觉定位

来料由视觉完成定位测算，无需人工干预

◆ 自适应性

系统能自适应生产不同尺寸的产品

◆ 柔性夹具

采用柔性抓手,适应各尺寸,薄厚材料

◆ 纠偏复合

在允许的切割误差范围内,系统经视觉AI计算,自动纠偏精准复合面料、填充层等。

多重系统保障生产效率

机器人复合系统

采用ABB机器人，结合本公司自研的纠偏复合手爪与AI专利技术及特别研制的视觉系统，具有对面料、海绵、乳胶等填充层材料、床芯内胆抓取后的自动纠偏功能，复合精度2-3mm，效率20-50s 。

立体视觉系统

德国映美精超⾼分辨率⼯业相机；

日本理光极低畸变镜头；

韩国QSI激光系统

UL认证纠偏手爪

采用伺服电机、SMC⽓缸、特制刺针，专门设计的嵌⼊式驱控一体电路板,嵌入式软件,增加压平机构,器件升级为UL认证。

数字孪生系统

以数字镜像模式，对机器人、复合对象、流程、系统设备等以数字化形式实现全生命周期的物联。

智能生产工序流程

中转站（需对接MES\WMS\SAP等系统）

床芯内胆、各材料从立库或AGV⾃动输送到位

床芯内胆自动拆垛上线或机器⼈⾃动抓取上线

自动贴入RFID

自动居中喷胶（PUR、热熔胶可选）

人工贴虎口及套围条

翻转机（笼式翻转机、双板翻转机）

二次居中喷胶（PUR、热熔胶可选）

自动复合底面料（机器人精准纠偏复合）

输送至第一次围边（自动围边机）

三次居中喷胶（PUR、热熔胶可选）

自动复合填充料（机器人精准复合）

第四次喷胶（PUR、热熔可选）

自动复合顶面料（机器人精准纠偏复合）

自动导入RFID床垫数据信息

输送至第二次围边（自动围边机）

除菌吹尘机（杀菌吹尘、吹尘机）

AI⾃动检验（或人工检验）

合格后自动包装（PE膜、牛皮纸、纸箱）

自动分拣-码垛机码垛

输送至立库（AVG小车）

智能化立库

Transfer Station (Requires integration with MES, WMS, SAP, and other systems）

Bed core and various materials are automatically transported from the vertical warehouse or AGV to the designated locations

Bed core is automatically unstacked and placed on the production line or robots automatically pick and place it

Automatic RFID tagging

Automatic central gluing (PUR, hot melt adhesive optional)

Manual application of edge tape and perimeter tape

Flip machine (cage-type or double-board flip machine)

Secondary central gluing (PUR, hot melt adhesive optional)

Secondary central gluing (PUR, hot melt adhesive optional)Automatic composite of bottom fabric (robot with precise alignment)

Transported to the first edge banding station (automatic edge banding machine

Third central gluing (PUR, hot melt adhesive optional)

Automatic composite of filling material (robot with precise alignment)

Fourth gluing (PUR, hot melt adhesive optional)

Automatic composite of top fabric (robot with precise alignment)

Automatically importing RFID mattress data information

Transported to the second edge banding station (automatic edge banding machine)

Transported to the second edge banding station (automatic edge banding machine)Decontamination and dusting machine (sterilization and dusting, or dusting only)

Al automatic inspection (or manualinspection)

Automatic packaging upon passing inspection (PE film, kraft paper, cardboard box)

Automatic sorting - stacking machine stacking

Transported to the vertical warehouse (AGV)

Automated vertical warehouse

技术特点

采用计算机智能控制系统导入 RFID 芯片技术，MES 管理系统及全自动化生产设备，MES、WMS 等管理系统，结合机器人自动生产线，使生产尽量无人化、智能化。

Adopt computer intelligent control system, import RFID chip technology, MES WMS and other management systems, and combine with robot automatic production line to make production as unmanned and intelligent as possible

整体自动化程度高，建立生产控制中心 PCC，和 MES 系统集成，通过大屏实现床垫生产过程信息的实时查看以及现场生产的可视化监控，具有较高的展示效果。

The overall degree of automation is high. The production control center PCC and MES system integration are established to realize the real-time viewing of mattress production process information and ready-made visual monitoring through the large screen, which has high display effect.

自动化程度高，配套自动床簧机、自动打钢边机、自动打底机、自动喷胶机、机器人自动床垫复合系统、自动压缩包装机、卷包机、自动码垛、AGV 自动运行小车，立体运输系统，朝生产无人化发展

High degree of automation, with automatic mattress spring machine, automatic steel edging machine, automatic bottoming, automatic glue spraying machine, automatic compressed packaging machine, mattress rolling machine, AGV automatic running vehicle, three-dimensional transportation system, towards unmanned development.

通过打造床垫的数字孪生技术车间，实现床垫生产、仓储、运输、销售、售后的全生命周期过程的实时监控和快速追溯。

By building digital workshop for mattresses, we can realize the real-time monitoring and rapid tracing of the whole life cycle process of mattress production, storage, transportation, sales and after-sales

整体布局紧凑合理，材料、成品都可用 AGV 小车自动配送及入库。

The overall layout is compact and reasonable, and materials and finished products can be automatically distributed and stored by AGV trolleys

随着产品定制时代的到来，可让客户随时在网上查看到定制产品的实时信息。

The overall layout is compact and reasonable. Materials and finished products can beautomatically delivered and warehoused by AFV trolley 。With the arrival of the era of product customization, customers can see the real-time information of customizednproducts on the Internet at any time.