Mattress production line

Bonell mattress production technology

In the production of bedroom furniture, mattresses made of traditional soft steel wire elastic springs are becoming more modern in terms of design. Production of products includes the following general work processes. Bonell mattress manufacturing processes begin with spring production and assembly. Then, the surface of the mattress is made of fabric combined with fabric and synthetic fiber. At the last stage, depending on the type and purpose of the combined spring block and the mattress, various fillers (foam rubber, latex, fabric waste, thermal felt, etc.) are prepared for the surface part, and the side part is combined with hardened fabrics and brought to the state of the finished product. .

Required raw materials:

Jacquard woven synthetic or cotton fabric; homeland; spunbond; strap; paralon or polyurethane foam.

High carbon steel wire with a diameter of 2.2 mm and a thickness of 5-6 mm.

Necessary infrastructures to start the activity:

Required area; Should not be less than 120 m².

Electric energy; 19 KW/220 and 380 V.

Number of workers; 8-12 people.

Equipment needed for this activity:

1. Bonell spring equipment.

2. Bonell spring assembly equipment.

3. Zigzag equipment.

4. Dimension cutting equipment.

5. Frame bending equipment.

6. Pneumatic clamping equipment.

7. Tape sewing machine.

8. Computer bladder machine.

9. Connecting sewing machine.

10. Air compressor.

Bonell spring equipment

Bonell spring equipment – The equipment has the ability to automatically make, weld, and cut springs. Depending on the diameter of the steel wire, it can be adjusted from 1.8 to 2.5 mm. The equipment has a production capacity of 55 pieces of bonell springs for 1 minute.

Technical indicator
Diametric of steel wire	1.8-2.4 mm
The outer diameter of the ring	65-85mm
Spring rate	80-200mm
Production speed	55 springs/min
Spring rotation	4-8
Voltage	380V
Power	4.5KV
Size	2280*1100*1660mm
Weight	1100 kg

 

 

 

Bonell spring harvesting equipment

Bonell spring assembly equipment – In the equipment, bonell springs are manually placed in a specially designated part, and then automatically coiled with steel wire.

Technical indicator
Spring width	2 m
Diametric of spiral steel wire	1.3-1.6mm
Spring length	80-220mm
Wire diameter	1.8-2.5mm
Voltage	380V
Power	4.5KV
Size	3100*960*1900mm
Weight	950 kg

 

Zigzag equipment

Zigzag equipment–the equipment works on the technology of automatic non-stop wire unwinding, forming and winding. The diameter of the steel wire is 2.5- 4.3 mm, and the wire is bent to form a zigzag appearance.

Technical indicator
Spring width	45-70 m m
Diametric of spiral steel wire	20-50mm
Diametric of the spring wire	2,5-4,3mm
Opportunity	38-180 hills/min
Power	380V50Hz
Size	1340*720*1900mm
Weight	800 kg

 

Equipment for cutting to size

Sizing equipment – this equipment straightens and cuts steel wires with a diameter of 3-6 mm. This equipment also has the option of automatic non-stop operation in fixed sizes. In the equipment, the wires cut to size are processed in the frame bending equipment.

Technical indicator
Frame length	7800mm
Wire diameter	3-60mm
Voltage	380V
Speed	1400 rpm
Power	4kv
Size	1460*495*1335 mm
Weight	675 kg

 

Frame bending equipment

Frame bending equipment – this device bends the side frames that support the mattress in the specified dimensions to form a frame. The equipment works with air cylinders.

Technical indicator
Wire diameter	3-5 mm
Air pressure	1.0 MPa
Frame width	800-1800mm
Frame length	1800-2300 mm
Opportunities	1000 pieces/hour
Size	2500*700*700mm
Weight	200 kg

 

 

Pneumatic clamping equipment

Pneumatic clamping device – a device that connects the carcass part with concentrated bonell springs, with special clamping details. The equipment works with an air compressor. In the production of bonell mattresses, this equipment completes the production processes of products with steel parts.

Technical indicator
Opportunity	40-50 pcs
Gross weight	4.03 kg
Net weight	3.3 kg
Size	410*210*90mm

 

Tape sewing machine

Ribbon Sewing Machine- The side fabrics connecting the upper and lower parts can be combined with ribbons or other types of fabric to create a new design. Machine sewing can be done automatically without interruption.

Technical indicator
Knitting width	10(14.20)*4.8(6.4)mm
Side fabric width	100-360mm
Sewing speed	10-14.4m/min
Voltage	380V
Power	0.58KV
Size(L*W)	3200*1600mm
Weight	520KG

Computerized bladder machine

Computer-aided sewing machine- This sewing machine automatically executes the sewing work specified on the basis of the drawing created by the computer. Bonell is adapted to the production possibilities of mattresses.

Technical indicator
Length	2-7mm
Needle speed	500-2500 needles/min
Speed	2000 rpm
Stitch size	2.0*2.2 m
The size of the fabric	2.3*2.5 m
Voltage	220V, 50Hz
Power	1.5KV
Size	2800*2900*1400 mm
Weight	700 kg

 

Joint sewing machine

Connecting sewing machine – a modern machine that sews upper and lower seams with a special tape. This machine can be adjusted to a size of 26 cm.

Technical indicator
Range	260 mm
Voltage	220V, 50Hz
Size	1930*1500*800mm
Weight	464 kg

 

Air compressor

Air Compressor – Auxiliary device for frame bending equipment and pneumatic crimping equipment.

Technical indicator
Pressure	0.8 Mpa
Cylinder(diametric*quantity)	90mm*3
Gas volume	250L
Packaging size	1630*670*1150mm
Gross weight	320 kg
Net weight	270 kg
Tension	380V
Power	7.5KV
Size	1530*520*1130

 

Video footage of the process