Coil spring interior assembly method and apparatus

Abstract

A spring interior forming method and apparatus provides a spring interior assembler and a coil row transfer station upstream of the assembler having at least one conveyer extending therethrough. A coil former is provided at an upstream end of the conveyor and is operated through a plurality of cycles, each to feed one spring coil onto the conveyor. In one embodiment, a single former is provided with a single conveyor extending therefrom through the transfer station. In a second embodiment, two such coiler-conveyor combinations is provided. In a third embodiment, one conveyor through the transfer station is provided with two coilers, each having a feeder preferably in the form of a conveyor, that selectively feed spring coils, which may be of different types, to a cross-over station for feed onto the transfer station conveyor. In a fourth embodiment, each coiler accumulates springs at its output while awaiting queing by the cross-over station. Between consecutive cycles of the feeding of a spring onto the transfer conveyor, a stepper motor or other servo-type motor advances the conveyor a programmed distance, thereby providing the capability for obtaining different programmed spacings between coils on the rows presented by the transfer conveyor to the transfer station.

Therefore, the following is claimed: 
     
       1. An spring interior assembly apparatus for forming spring interior assemblies of arrays of parallel rows of springs, comprising: a spring interior assembler;   a spring row transfer station upstream of the assembler and operative to transfer a prearranged row of springs from at least one row transfer position to the assembler,   a conveyer moveable to carry a prearranged row of formed springs to the transfer position;   a spring former having an outfeed end;   a spring feeder located between the spring former and the conveyor and operative to feed formed springs individually from the spring former to a predetermined position on the conveyor;   a servo motor driveably connected to conveyor to move formed springs held at predetermined positions thereon to the transfer position; and   a controller programmed to variably control the relative operation of the servo motor and feeder independently of the respective spring former.   
     
     
       2. The apparatus of claim 1 wherein: the controller is variable so as to variably control the operation of the servo motor and feeder so as to affect and control the spacing of springs at the predetermined positions on the conveyor.   
     
     
       3. The apparatus of claim 1 wherein: the spring row transfer station is operative to transfer a prepositioned plurality of springs from each of at least two row transfer positions to the assembler;   the spring former includes at least two spring formers each having an outfeed end;   the conveyer includes at least two conveyors each moveable to carry a prepositioned plurality of formed springs from a respective one of the spring formers to one of the row transfer positions;   the spring feeder includes at least two feeders, each located between the outfeed end of one spring former and a respective one of the conveyors and operative to feed springs individually from the respective spring former each to a predetermined position on the respective conveyor;   the servo motor includes at least two servo motors each driveably connected to a respective one of the conveyors to move formed springs held at predetermined positions on the respective conveyor to the respective row transfer position; and   the controller is programmed to variably control the relative operation of the servo motors and feeders so as to affect the spacing of springs at the predetermined positions on the respective conveyor.   
     
     
       4. The apparatus of claim 3 wherein: the controller is variable so as to variably control the operation of the servo motors and feeders so as to affect and control the spacing of springs at the predetermined positions on the conveyors.   
     
     
       5. The apparatus of claim 3 wherein: the spring row transfer station is operative to transfer prepositioned pluralities of springs from each of at least two row transfer positions into a single row of springs having a predetermined arrangement of the prepositioned pluralities; and   the controller being programmed to variably control the relative operation of the servo motors and feeders so as to affect the predetermined arrangement.   
     
     
       6. The apparatus of claim 3 wherein: the spring row transfer station is operative to transfer pluralities of springs prepositioned in prearranged rows from each of the transfer positions to the assembler; and the controller being programmed to control operation of the transfer station to transfer prearranged rows of springs alternately from each of the transfer positions.   
     
     
       7. The apparatus of claim I wherein: the spring former includes at least two spring formers each having an outfeed end;   the spring feeder is located between the outfeed ends at least two of the spring formers and the conveyor and is operative to feed springs individually and selectively from each of the spring formers to a predetermined position on the conveyor; and   the controller is programmed to variably control the relative operation of the servo motor and feeder so as to affect the selective positioning of springs from the spring formers at the predetermined positions on the conveyor.   
     
     
       8. The apparatus of claim 7 wherein: the spring formers are each operative to form springs of differing configurations; and   the controller is programmed to variably control the relative operation of the servo motor and feeder so as to affect the selective positioning of springs from the spring formers at the predetermined positions on the conveyor.   
     
     
       9. The apparatus of claim 7 wherein: the spring feeder includes at least two infeed conveyor sections, each located between the outfeed end of one of the spring formers and the conveyor, each spring former being cyclically operative, in response to a trigger signal, to form a spring and deposit the formed spring onto a corresponding conveyor section; and   the controller is programmed to selectively generate trigger signals to each of the .[.coil.]. .Iadd.spring .Iaddend.formers to affect the formation of springs thereby and to variably control the relative operation of the conveyor sections in synchronization with the operation of the servo motor so as to affect the selective positioning of springs from the spring formers at the predetermined positions on the conveyor.   
     
     
       10. The apparatus of claim 7 wherein: the spring feeder includes at least two infeed conveyor sections, each located between the outfeed end of one of the spring formers and the conveyor, each spring former being cyclically operative, in response to a trigger signal, to form a spring and deposit the formed spring onto a corresponding conveyor section;   each infeed conveyor section including a spring accumulator mechanism operable to receive formed springs deposited at arbitrary positions thereon by a spring former, the accumulator mechanism being controllable to release springs for selective positioning on the conveyor at the predetermined positions therefor; and   the controller is programmed to coordinate the operation of the accumulator mechanism, spring formers and conveyor sections to facilitate optimum utilization of the spring formers.   
     
     
       11. The apparatus of claim I further comprising: means, including the controller, for variably controlling the operation of the servo motor and feeder and for affecting and controlling the spacing of springs at the predetermined positions on the conveyor.   
     
     
       12. The apparatus of claim 1 wherein: the spring row transfer station includes means for transferring a prepositioned plurality of springs from each of at least two row transfer positions to the assembler;   the spring former includes at least two spring formers each having an outfeed end;   the conveyer includes means including at least two conveyors for carrying a prepositioned plurality of formed springs from a respective one of the spring formers to one of the row transfer positions;   the spring feeder includes at least two feeders, each located between the outfeed end of one spring former and a respective one of the conveyors and operative to feed springs individually from the respective spring former each to a predetermined position on the respective conveyor;   the servo motor includes means for moving each respective one of the conveyors and formed springs held at predetermined positions thereon to the respective row transfer position; and   the controller includes means for variably controlling the relative operation of the moving means and feeders and for affecting the spacing of springs at the predetermined positions on the conveyors.   
     
     
       13. The apparatus of claim 12 wherein: the controller includes means for variably controlling the operation of the moving means and feeders and for affecting and controlling the spacing of springs at the predetermined positions on the conveyors.   
     
     
       14. The apparatus of claim 12 wherein: the spring row transfer station includes means for transferring prepositioned pluralities of springs from each of at least two row transfer positions into a single row of springs having a predetermined arrangement of the prepositioned pluralities; and   the controller includes means for variably controlling the relative operation of the moving means and feeders and for affecting the predetermined arrangement.   
     
     
       15. The apparatus of claim 12 wherein: the spring row transfer station includes means for transferring pluralities of springs prepositioned in prearranged rows from each of the transfer positions to the assembler; and   the controller includes means for controlling the operation of the transfer station to transfer prearranged rows of springs alternately from each of the transfer positions.   
     
     
       16. The apparatus of claim 1 wherein: the spring former includes at least two spring formers each having an outfeed end;   the spring feeder is located between the outfeed ends at least two of the spring formers and the conveyor;   the apparatus includes means including the feeder for feeding springs individually and selectively from each of the spring formers to a predetermined position on the conveyor; and   the controller includes means for variably controlling the relative operation of the servo motor and feeder so as to affect the selective positioning of springs from the spring formers at the predetermined positions on the conveyor.   
     
     
       17. The apparatus of claim 16 wherein: the spring formers are each operative to form springs of differing configurations; and   the controller includes means for variably controlling the relative operation of the servo motor and feeder and for affecting the selective positioning of springs from the spring formers at the predetermined positions on the conveyor.   
     
     
       18. The apparatus of claim 16 further comprising: means for variably controlling the relative operation of the components of the machine to affect the selective positioning of springs from the spring formers at the predetermined positions on the conveyor.   
     
     
       19. The apparatus of claim 16 wherein: the spring feeder includes means for accumulating formed springs and for releasing springs for selective positioning on the conveyor at the predetermined positions therefor.   
     
     
       20. A method of forming spring interiors comprising the steps of: providing a spring interior assembler;   providing a coil row transfer station upstream of the assembler;   providing at least one conveyer extending through the transfer station;   providing a coil former adjacent the conveyor;   operating the coil former through a plurality of cycles, each to form one spring;   feeding each formed spring onto the conveyor upstream of the transfer station;   between each feeding of a spring onto the conveyor, advancing the conveyor an independent distance so as to affect independent spacings between adjacent springs on the conveyor;   advancing a row of springs to the transfer station;   transferring the advanced row of springs from the transfer station to the assembler;   repeating the operating, feeding advancing and transferring steps; and   with the assembler, assembling a plurality of transferred rows of springs into a spring interior. .Iadd.   
     
     
       21.  A spring interior assembly apparatus for forming spring interior assemblies of arrays of parallel rows of springs, comprising: a spring interior assembler;   a spring row transfer station upstream of the assembler and operative to transfer a prearranged row of springs from at least one row transfer position to the assembler;   a conveyer moveable to carry a prearranged row of formed springs to the transfer position;   at least two spring formers, each having an outfeed end;   a spring feeder located between each spring former and the conveyor and operative to feed formed springs individually from the spring formers to predetermined positions on the conveyor;   a servo motor driveably connected to the conveyor to move formed springs held at predetermined positions thereon to the transfer position; and   a controller programmed to variably control the relative operation of the servo motor and feeder..Iaddend..Iadd.   
     
     
       22.  The apparatus of claim 21 wherein: the controller is programmed to variably control the relative operation of the spring formers..Iaddend..Iadd.23. The apparatus of claim 21 wherein:   the controller is variable so as to variably control the operation of the servo motor and feeder so as to affect and control the arrangement of springs at the predetermined positions on the conveyor..Iaddend..Iadd.24. The apparatus of claim 21 wherein:   the spring row transfer station is operative to transfer a prepositioned plurality of springs from each of at least two row transfer positions to the assembler;   the conveyer includes at least two conveyors each moveable to carry a prepositioned plurality of formed springs from a respective one of the spring formers to one of the row transfer positions;   the spring feeder includes at least two feeders, each located between the outfeed end of one spring former and a respective one of the conveyors and operative to feed springs individually from the respective spring former each to a predetermined position on the respective conveyor;   the servo motor includes at least two servo motors each driveably connected to a respective one of the conveyors to move formed springs held at predetermined positions on the respective conveyor to the respective row transfer position; and   the controller is programmed to variably control the relative operation of the servo motors and feeders so as to affect the spacing of springs at the predetermined positions on the respective conveyor..Iaddend..Iadd.25. The apparatus of claim 24 wherein:   the controller is variable so as to variably control the operation of the servo motors and feeders so as to affect and control the spacing of springs at the predetermined positions on the conveyors..Iaddend..Iadd.26. The apparatus of claim 24 wherein:   the spring row transfer station is operative to transfer prepositioned pluralities of springs from each of at least two row transfer positions into a single row of springs having a predetermined arrangement of the prepositioned pluralities; and   the controller being programmed to variably control the relative operation of the servo motors and feeders so as to affect the predetermined arrangement..Iaddend..Iadd.27. The apparatus of claim 24 wherein:   the spring row transfer station is operative to transfer pluralities of springs prepositioned in prearranged rows from each of the transfer positions to the assembler; and   the controller being programmed to control operation of the transfer station to transfer prearranged rows of springs alternately from each of the transfer positions..Iaddend..Iadd.28. The apparatus of claim 21 wherein:   the spring feeder is located between the outfeed ends of the spring formers and the conveyor and is operative to feed springs individually and selectively from each of the spring formers to a predetermined position on the conveyor; and   the controller is programmed to variably control the relative operation of the servo motor and feeder so as to affect the selective positioning of springs from the spring formers at the predetermined positions on the conveyor..Iaddend..Iadd.29. The apparatus of claim 28 wherein:   the controller is programmed to variably control the relative operation of   
     
     
        the spring formers..Iaddend..Iadd.30.  The apparatus of claim 28 wherein: the spring formers are operative to form springs of differing configurations; and   the controller is programmed to variably control the relative operation of the servo motor and feeder so as to affect the selective positioning of springs from the spring formers at the predetermined positions on the conveyor..Iaddend..Iadd.31. The apparatus of claim 30 wherein:   the controller is programmed to variably control the relative operation of the spring formers..Iaddend..Iadd.32. The apparatus of claim 28 wherein:   the spring feeder includes at least two infeed conveyor sections, each located between the outfeed end of one of the spring formers and the conveyor, each spring former being cyclically operative, in response to a trigger signal, to form a spring and deposit the formed spring onto a corresponding conveyor section; and   the controller is programmed to selectively generate trigger signals to each of the spring formers to affect the formation of springs thereby and to variably control the relative operation of the conveyor sections in synchronization with the operation of the servo motor so as to affect the selective positioning of springs from the spring formers at the predetermined positions on the conveyor..Iaddend..Iadd.33. The apparatus of claim 28 wherein:   the spring feeder includes at least two infeed conveyor sections, each located between the outfeed end of one of the spring formers and the conveyor, each spring former being cyclically operative, in response to a trigger signal, to form a spring and deposit the formed spring onto a corresponding conveyor section;   each infeed conveyor section including a spring accumulator mechanism operable to receive formed springs deposited at arbitrary positions thereon by a spring former, the accumulator mechanism being controllable to release springs for selective positioning on the conveyor at the predetermined positions therefor; and   the controller is programmed to coordinate the operation of the accumulator mechanism, spring formers and conveyor sections to facilitate optimum utilization of the spring formers..Iaddend..Iadd.34. The apparatus of claim 28 further comprising:   means, including the controller, for variably controlling the operation of the servo motor and feeder and for affecting and controlling the spacing of springs at the predetermined positions on the   
     
     
        conveyor..Iaddend..Iadd.  .  A method of forming spring interiors comprising the steps of: providing a spring interior assembler;   providing a coil row transfer station upstream of the assembler;   providing at least one conveyer extending through the transfer station;   providing at least two coil formers adjacent the conveyor;   operating the coil formers through a plurality of cycles, each cycle to form one spring;   feeding each formed spring onto the conveyor upstream of the transfer station;   after the feeding of a spring onto the conveyor, advancing the conveyor a distance so as to affect spacings between adjacent springs on the conveyor;   advancing a row of springs to the transfer station;   transferring the advanced row of springs from the transfer station to the assembler;   repeating the operating, feeding advancing and transferring steps; and   with the assembler, assembling a plurality of transferred rows of springs into a spring interior..Iaddend..Iadd.36. A method of forming spring interiors comprising the steps of:   providing a spring interior assembler;   providing a coil row transfer station upstream of the assembler;   providing at least one conveyer extending through the transfer station;   feeding a plurality of formed springs onto the conveyor upstream of the transfer station;   after each feeding of a spring onto the conveyor, advancing the conveyor a distance so as to affect at least two different spacings between different pairs of adjacent springs on the conveyor;   advancing a row of springs to the transfer station;   transferring the advanced row of springs from the transfer station to the assembler;   repeating the operating, feeding advancing and transferring steps; and   with the assembler, assembling a plurality of transferred rows of springs into a spring interior..Iaddend..Iadd.37. The method of claim 36 wherein:   the feeding step includes the steps of providing at least two coil formers adjacent the conveyor and operating the coil formers through a plurality of cycles, each cycle to form one spring..Iaddend..Iadd.38. The method of claim 36 wherein:   the feeding step includes the steps of providing at least one coil former adjacent the conveyor and operating the coil former through a plurality of cycles, each cycle to form one spring..Iaddend..Iadd.39. The method of claim 38 further comprising the step of:   controlling the coil former, feeder and conveyor to synchronize the operation of the coil former and the feeding step with the advancing of the conveyor so that formed springs are placed onto the conveyor in a preprogrammed arrangement of the different spring spacings..Iaddend..Iadd.40. A method of forming spring interiors comprising the steps of:   providing a spring interior assembler;   providing a coil row transfer station upstream of the assembler;   providing at least one conveyer extending through the transfer station;   providing at least one coil former adjacent the conveyor and operating the coil former through a plurality of cycles, each cycle to form one spring;   feeding a plurality of formed springs from the at least one coil former onto the conveyor upstream of the transfer station;   after feeding a spring onto the conveyor, advancing the conveyor a distance so as to affect a spacing between adjacent springs on the conveyor;   advancing a row of springs to the transfer station;   the spring feeding and conveyor advancing steps being controllable independent of the controlling of the coil former, and being coordinated by a controller;   transferring the advanced row of springs from the transfer station to the assembler;   repeating the operating, feeding advancing and transferring steps; and   with the assembler, assembling a plurality of transferred rows of springs into a spring interior..Iaddend..Iadd.41. The method of claim 36 wherein:   the feeding step includes the step of feeding a plurality of formed springs which differ..Iaddend..Iadd.42. A method of forming spring interiors comprising the steps of:   providing a spring interior assembler;   providing a coil row transfer station upstream of the assembler;   providing a conveyer extending through the transfer station;   feeding a plurality of formed springs of at least two types which differ in wire size, each from a coil former onto said conveyor upstream of the transfer station;   advancing the conveyor to affect spacings between adjacent springs fed onto the conveyor;   advancing a row of springs to the transfer station;   transferring the advanced row of springs from the transfer station to the assembler;   repeating the operating, feeding advancing and transferring steps; and   with the assembler, assembling a plurality of transferred rows of springs into a spring interior..Iaddend..Iadd.43. A method of forming spring interiors comprising the steps of:   providing a coil row transfer station upstream of a spring interior assembler;   providing a conveyer extending through the transfer station;   feeding a plurality of formed springs from at least one coil former onto the conveyor upstream of the transfer station, in a predetermined arrangement on the conveyor of springs differing in characteristics selected from the group consisting of spring type, spring shape, spring size, spring stiffness, spring strength, and spring configuration;   advancing the conveyor to affect spacings between adjacent springs fed onto the conveyor;   advancing a row of springs to the transfer station;   transferring the advanced row of springs from the transfer station to the assembler;   repeating the operating, feeding advancing and transferring steps; and   with the assembler, assembling a plurality of transferred rows of springs into a spring interior..Iaddend.