Description
Overview
Automatic bonnell transfer machine built to achieve the highest productivity with the maximum speed in the production of bonnell spring units.
Bonnell production in 5 steps: the steel wire gets formed to a spring in the coiling machine; the springs are getting knotted at both ends; the springs get heat treated between two electrodes; the springs are getting transferred to the assembly machine; a spiral wire assembles the springs to get a finished spring unit.
Tensile strength for the wire is 1700 to 1850 N/mm².
Highlights
Consistent high performance: maximum speed for any type of bonnell spring unit; no slowdown during production of spring units for furniture.
Improved transfer mechanism: patented technology; faster springs turning from horizontal to vertical position.
More flexible production: simple production of different spring unit types; changeover within few seconds on the touchscreen display; very flexible and quick setting of the spring unit width.
Full automated program: automation program ensures the production of different spring unit types without intervention; number of the requested spring units can be easily set on the touchscreen display; the automation program increases the productivity of spring unit manufacturer.
Optimized design for furniture spring units: system offers the production of l-type spring units; the system allows the production of spring unit with no corners in certain areas for furniture spring units.
Spiral Knotting Options
4-5 knotting system: the 4-5 knotting of the spiral wire allows the production of spring units with maximum firmness; this system reduces the range of motion for the bonnell springs.
4-4 knotting system: the 4-4 knotting of the spiral wire ensures the production of spring units with medium firmness; this system allows a small degree of motion for the bonnell springs; the working range of this knotting system is for springs in the diameter between 80-96mm and wire diameter between 1.9 - 2.4mm.
4-3 knotting system: the 4-3 spiral wire knotting provides the production of bonnell springs with maximum range of motion; this knotting system is designed for mini bonnell springs in the diameter 70-78mm and the wire diameter 1.9 - 2.2mm; this system offers the ideal solution to increase the number of springs on bonnell spring units.
Automatic Lubrication System
The automatic lubrication system ensures a periodic oiling of 22 points on the machine.
The time frame for the periodic lubrication can be easily set up on the display.
Digital Heat Treatment
The digital heat treatment provides maximum durability to the bonnell springs.
The temperature can be easily set up on the display.
The heat treatment ensures that every spring is stress-relieved and strengthened.
This process eliminates spring sag.
Easy Height Settings
Offers the easiest height setting technology which can be adjusted on the touchscreen display.
This feature enables spring height adjustment completely automatically.
Spring height adjustments are made on the precise linear adjustment tool.
Easy Handling and High Security Standards
The simple accessibility allows for more adjustments on the jaw system.
The opening system of the assembly part is working completely automatic and there is no need to push or pull on the machine.
The safety light curtains protects the operator of the machine.
During the adjustments by operator the safety system does not allow the closing of the assembly part of the machine.
Operation
Produces and assembles bonnell springs into spring units automatically in a high production speed.
The steel wire is located at the wire basket; this wire gets unwounded, coiled and cut to a raw spring; this raw spring is afterwards getting knotted at both ends and heat treated; in the next step the springs are swung from a horizontal to a vertical position and at the same time rotated around their axes and inserted into a belt conveyor; in this way all springs are ready to be assembled row by row.
If programmed spring unit width is reached by necessary number of springs, the belt conveyor stops and all springs of one row are pushed by loading slides into the jaws of assembly machine; the jaw system is getting closed and two spiral wires connecting the springs on the top and bottom to form a spring unit; both spiral wires are being cut and bent at both ends joining this and the previous row.
When the cycle of one spring row is concluded, the spring unit is getting pushed one step forward.
This machine works without compressed air; it works with a clearly structured concept with an integrated motion control unit which is able to demonstrate, report and follow all product parameters and features on touchscreen control panel; each jaw may be used as a knuckling jaw which allows a quick change-over to different spring unit widths up to 2000mm.
Output
Up to 80 springs per minute or 38,400 springs in 8 hours.
Springs with a tall height or unstable geometry lead to a reduced performance of the machine.
The production capacity is approx. 210 spring units for single size or 130 spring units for double size mattresses per 8 hours of working time.
Equipment
Automatic bonnell transfer machine includes 6 main parts: a. heavy-duty swift basket useable for up to 1000 kg of wire, including safety cage and switches; b. automatic bonnell coiling machine with two knotting systems and a heat treatment unit, automatic lubrication system and a safety cage; c. transfer mechanism; d. conveyor system with safety cage and loading equipment includes 18 loading sliders; e. automatic assembly machine with a maximum working width of up to 2000mm and 18 jaws; f. electronic system with mitsubishi motion control system which works with 8 servo motors.
Technical Specifications
Spring type: bonnell.
Performance: 80 springs/minute.
Production capacity: 38,400 springs/8 hours; approx. 210 spring units for single size bed/8 hours (900 x 1900mm, 8x23 springs); approx. 130 spring units for double size bed/8 hours (1400 x 1900mm, 13x23 springs).
Spring outside diameter: 70mm - 96mm; standard: 80-92mm, max. 18 jaws, 1.9-2.4mm; optional: 80-96mm, max. 18 jaws, 1.9-2.4mm; 70-78mm, max. 23 jaws, 1.9-2.2mm; 70-75mm, max. 25 jaws, 1.9-2.2mm.
Spring height diameter: 75mm - 160mm; standard: 120mm - 140mm (5 turns); optional: 75mm - 120mm (4 turns); 140mm - 160mm (6 turns).
Spring wire diameter: 1.9mm - 2.4mm.
Spiral wire diameter: 1.3mm - 1.4mm.
Working width: 2000mm.
Power consumption: approx. 18 kw.
Power requirements: three phase 380v; frequency: 50-60 hz; input fuse: 63 a; cable: 4 x 10mm².
Working temperature: 0° c - 40° c.
Weight: approx. 4800kg.
Wire basket capacity: 1000 kg.
Spiral wire basket capacity: 2 x 850 kg.
Control system: mitsubishi motion control system.
