Design Proposal for an Efficient Automated Mattress Production Line
Customer Requirements
(1) Daily Production Target: Ensure daily production of over 300 mattresses to meet market demand；
(2) Factory Space Requirement: A production workshop of approximately 1,000 square meters, requiring rational layout planning to maximize production efficiency.
(3) Staffing Configuration: The entire production line is expected to be staffed with approximately 9 operators to ensure smooth production and controllable labor costs.
Our Design
1. Initial Glue Spraying and Allocation Stage:
(1) Glue Spraying Process: Mattresses undergo basic glue spraying at the initial glue spraying station to ensure adhesion strength of internal materials.
(2) Automatic Allocation on Line A: After glue spraying, mattresses are automatically placed onto the conveyor belt of Line A. Line A is equipped with an intelligent recognition system that automatically allocates mattresses to different processing paths based on their type (whether they require secondary glue spraying).
2. Automated Tape Edge Machine Station:
(1) Automated Tape Edge: Mattresses, after passing through Line A, are precisely allocated to individual automated edge-wrapping machine stations. The edge-wrapping machines utilize high-precision robotic arms to quickly and evenly complete the edge-wrapping process, enhancing the aesthetics and durability of the mattresses.
(2) Linear Transfer: Mattresses with completed edge-wrapping are sent to Line B for the next process.
3. Secondary Glue Spraying Reflow Design
(1) Reflow Mechanism: For mattresses requiring secondary glue spraying, Line A features an upper reflux path that directly guides them to a second glue spraying machine for supplementary glue application. This design eliminates manual handling and enhances production efficiency.
(2) Re-edge-wrapping: After secondary glue spraying, mattresses pass through Line A again to the next edge-wrapping machine station, ensuring all mattresses meet quality standards.
4. Automated Packaging Line:
(1) Connection to Line C: Mattresses that do not require secondary glue spraying, as well as those that have completed all necessary processes, seamlessly transition from Line B to Line C.
(2) Automatic Packaging: At the end of Line C, a fully automated packaging machine is configured to efficiently and accurately complete the packaging of mattresses. Packaging material selection and sealing methods can be customized according to customer requirements, ensuring product safety and integrity during transportation.
Summary
This design proposal fully considers the customer's daily production volume, factory space, and staffing requirements. By introducing automation technology and intelligent management systems, it achieves efficient, flexible, and precise control of mattress production. It not only improves production efficiency and reduces labor costs but also ensures stability and consistency in product quality, providing strong support for the customer's business development.
