Spring setting device, apparatus for forming a string of pocket springs, and method of setting springs

Abstract

A spring setting device (30) comprises a setting guide (31; 40) configured to receive a spring, an abutment member (32; 50) positioned adjacent to the setting guide (31; 40) and configured to abuttingly engage the spring, and a pusher (35; 71) which is configured to displace the spring along the setting guide (31; 40) and to compress the spring against the abutment member (32; 50). The abutment member (32; 50) may be rotatably mounted.

Claims

1. A spring setting device, comprising: a setting guide configured to receive a spring; an abutment member positioned adjacent to the setting guide and configured to abuttingly engage the spring, the abutment member being rotatably mounted; and a pusher which is configured to displace the spring along the setting guide and to compress the spring against the abutment member; wherein the pusher is attached to an endless conveyor, the abutment member extends in a plane, the spring setting device is configured to move the pusher across the plane in which the abutment member extends, and the abutment member comprises at least one recess dimensioned to allow the pusher to pass therethrough.

2. The spring setting device of claim 1, wherein the spring setting device is configured such that a direction of rotation of the endless conveyor remains unchanged during operation of the spring setting device.

3. The spring setting device of claim 1, wherein at least one further pusher is attached to the endless conveyor.

4. The spring setting device of claim 1, wherein the abutment member is configured to effect a displacement of a set spring, the displacement effected by the abutment member being directed transversely to a longitudinal axis of the setting guide.

5. The spring setting device of claim 4, wherein the spring setting device is configured such that the pusher is maintained stationary while the abutment member effects the displacement of the spring.

6. The spring setting device of claim 1, further comprising: a control device configured to control a movement of the pusher and of the abutment member in a coordinated manner.

7. An apparatus for forming a string of pocket springs, comprising: a spring former configured to form a spring; a spring setting device of claim 1 configured to set the spring; and a pocketing device configured to enclose the set spring in an associated pocket.

8. The apparatus of claim 7, further comprising: a partition, wherein the spring former is mounted on a first side relative to the partition, the pocketing device is mounted on a second side relative to the partition, the second side being opposite to the first side, and the setting guide of the spring setting device extends from the first side to the second side.

9. A method of setting a spring, the method comprising: displacing, by a pusher, the spring along a setting guide, wherein the pusher is attached to an endless conveyor; and compressing, by the pusher, the spring on an abutment member which is rotatably mounted and positioned adjacent the setting guide, the abutment member abuttingly engaging the spring and using the pusher to push the spring through at least one recess of the abutment member, the recess being dimensioned to allow the pusher to pass the spring therethrough.

10. The method of claim 9, which is performed by the spring setting device of claim 1.

11. The method of claim 9, which is performed by the apparatus of claim 7.

12. A spring setting device, comprising: a setting guide configured to receive a spring; an abutment member positioned adjacent to the setting guide and configured to abuttingly engage the spring, the abutment member being movably mounted; and a pusher which is configured to displace the spring along the setting guide and to compress the spring against the abutment member, wherein the abutment member extends in a plane, the spring setting device is configured to move the pusher across the plane in which the abutment member extends, and the abutment member comprises at least one recess dimensioned to allow the pusher to pass therethrough.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Embodiments of the invention will be described in detail with reference to the drawings in which like reference numerals designate like elements.

(2) FIG. 1 shows a schematic view of an apparatus according to an embodiment.

(3) FIG. 2 shows a perspective view of a spring setting device according to an embodiment.

(4) FIG. 3 shows a front view of the spring setting device of FIG. 2 with viewing direction along a longitudinal axis of a spring guide.

(5) FIG. 4 shows a partially broken-away view of the spring setting device of FIG. 2.

(6) FIG. 5 is a diagram illustrating actuation of a pusher drive mechanism and of an abutment member drive mechanism in the spring setting device according to an embodiment.

(7) FIG. 6A and FIG. 6B show a partially cross-sectional view and a front view, respectively, of the spring setting device of FIG. 2 during an operation cycle.

(8) FIG. 7A and FIG. 7B show a partially cross-sectional view and a front view, respectively, of the spring setting device of FIG. 2 at a later time in the operation cycle.

(9) FIG. 8A and FIG. 8B show a partially cross-sectional view and a front view, respectively, of the spring setting device of FIG. 2 at a later time in the operation cycle.

(10) FIG. 9A and FIG. 9B show a partially cross-sectional view and a front view, respectively, of the spring setting device of FIG. 2 at a later time in the operation cycle.

(11) FIG. 10A and FIG. 10B show a partially cross-sectional view and a front view, respectively, of the spring setting device of FIG. 2 at a later time in the operation cycle.

(12) FIG. 11A and FIG. 11B show a partially cross-sectional view and a front view, respectively, of the spring setting device of FIG. 2 at a later time in the operation cycle.

(13) FIG. 12 is a flow chart of a method according to an embodiment.

(14) FIG. 13 is a flow chart of a method according to an embodiment.

DESCRIPTION OF EMBODIMENTS

(15) Embodiments of the invention will be described with reference to the drawings in which like reference numerals designate like elements.

(16) While embodiments of the invention will be described in the context of specific applications of a spring setting device, it will be appreciated that the embodiments are not limited thereto. For illustration, while some embodiments will be described in the context of a spring setting device which is integrated in an apparatus which also includes a spring former and/or a pocketing device, the configuration of the spring setting device according to embodiments is not limited thereto. For further illustration, while some embodiments will be described in the context of a process and apparatus for forming a string of pocket springs, the devices and methods according to embodiments may also be used for manufacturing unpocketed innerspring units.

(17) FIG. 1 illustrates an apparatus 1 for forming a string 6 of pocket springs 7, 8 according to an embodiment.

(18) The apparatus 1 may comprise a spring former 21 which winds springs and a cooling channel 22 in which the wound springs are allowed to cool down. The cooling channel 22 may comprise a plurality of receptacles, each configured to receive a spring. The cooling channel may be in communication with an inlet opening of a setting guide.

(19) The apparatus 1 comprises a spring setting device 30 according to an embodiment which will be described in more detail with reference to FIG. 2 to FIG. 13. The spring setting device 30 is operative to set a spring, i.e., to compress the spring for the first time after it has been wound. As will be described in more detail below, the spring setting device 30 may fulfil further functions. In the apparatus 1 of FIG. 1, the spring setting device 30 may be operative to transfer the spring 9 from a first side 11 of the spring setting device to a second side 12, thereby fulfilling a transfer function across a partition 3 which extends between the first side 11 and the second side 12.

(20) The apparatus 1 may comprise a pocketing device 23 for pocketing the spring which was set by the spring setting device 30. The pocketing device 23 may be configured to enclose the spring in an associated pocket of fabric. Fabric may be supplied to the pocketing device 23 from a supply 24, which may be a roll of fabric. The fabric may be a non-woven fabric. The fabric may be folded to form a tube 25 of pocket material in which the spring 9 is inserted. The pocketing device 23 may comprise at least one unit for forming a seam on the tube of folded fabric. The pocketing device 23 may comprise a first ultrasonic welding unit for forming a longitudinal welded seam extending along a longitudinal axis of the folded fabric. The pocketing device 23 may comprise a second ultrasonic welding unit 26 for forming transverse seams which extend between the pockets of the string 6.

(21) The apparatus 1 may comprise a base 2. The spring former 21, the spring setting device 30 and the pocketing device 23 may be directly or indirectly mounted to the base 2. A barrier 3 may extend vertically from the base 2. The barrier 3 may separate the first side 11 of the apparatus 1, which is prone to producing significant amounts of dust or dirt, from the second side 12 of the apparatus 1 where it is desired to keep the fabric clear of contaminations which may originate from the first side 11.

(22) The spring setting device 30 generally comprises a setting guide 31, a pusher 33, and an abutment member 32. The setting guide 31 may have a longitudinal axis. The longitudinal axis may be generally horizontal. The setting guide 31 may be a setting tube having a slot for allowing the pusher 33 to be advanced therein.

(23) The abutment member 32 is movably mounted. As will be explained in more detail below, the abutment member 32 may be rotatably mounted. A rotation axis of the abutment member 32 may extend parallel to the longitudinal axis of the setting guide 31. Any other configuration may be used which allows an abutment surface of the abutment member 32 to be positioned to face an outlet opening of the setting guide 31 when a spring is to be compressed thereon, and to be displaced so as to keep the outlet opening of the setting guide 31 clear of the abutment member to allow the pusher 33 to move past a plane in which the abutment member 32 extends. The abutment member 32 may comprise at least one and preferably plural recesses, which respectively allow the pusher 33 to pass threrethrough.

(24) An endless conveyor 34 may be provided for displacing the pusher 33. Further pushers may be attached to the endless conveyor 34. The endless conveyor 34 may extend along the setting guide 31. The endless conveyor 34 may comprise an endless belt.

(25) The endless conveyor 34 is positioned such that the pusher 33 is advanced in the setting guide 31 to move the spring 9 into abutment with the abutment surface 32 and to compress the spring 9 against the abutment surface 32. The endless conveyor 34 may be positioned such that the pusher 33 travels back from the outlet opening to an inlet opening of the setting guide 31 along a patch which is offset from the setting guide 31. For illustration, the return path of the pusher 33 may be vertically offset from the path along the setting guide in which it is advanced towards the abutment member 32.

(26) The spring setting device 30 may comprise a pusher drive mechanism 28 and an abutment member drive mechanism 29. A control device 27 may control operation of the pusher drive mechanism 28 and of the abutment member drive mechanism 29.

(27) The spring setting device 30 may operate the pusher drive mechanism 28 and the abutment member drive mechanism 29 in such a way that the pusher 33 and the abutment member 32 are displaced intermittently. The spring setting device 30 may operate the pusher drive mechanism 28 and the abutment member drive mechanism 29 in such a way that a phase in which the pusher 33 is moved while the abutment member 32 is stationary alternates with another phase in which the pusher 33 is stationary while the abutment member 32 is rotated.

(28) The control device 27 may control movement of the pusher 33 and of the abutment member 32 in such a manner that the pusher 33 is moved by a first distance to compress the spring 9 while the abutment member 32 is kept stationary. The control device 27 may thereafter control movement of the abutment member 32 in such a manner that displacement of the abutment member 32 removes the compressed spring from the outlet opening of the setting guide 31 and the abutment member 32 is positioned in a non-overlapping relationship with the pusher 33. The control device 27 may thereafter control movement of the pusher 33 in such a manner that the pusher 33 is moved by a second distance to move the pusher 33 past the plane in which the abutment member 32 extends. The second distance may be smaller than the first distance. A discharge mechanism (not shown in FIG. 1) may be operated simultaneously to discharge a previously compressed spring from the abutment member 32. The control device 27 may thereafter control movement of the abutment member 32 in such a manner that another abutment surface of the abutment member is positioned in front of the outlet opening of the setting tube 31, in order to allow a further spring to be set.

(29) The apparatus 1 may comprise additional components. For illustration, a first enclosure 4 may be provided to at least partially enclose the components positioned on the first side 11. A second enclosure 5 may be provided to at least partially enclose the components positioned on the first side 12.

(30) A spring setting device 30 according to an embodiment will be described in more detail with reference to FIG. 2 to FIG. 13.

(31) FIG. 2 shows a perspective view of a spring setting device 30 according to an embodiment. The spring setting device 30 may be installed in the apparatus 1 of FIG. 1.

(32) The spring setting device 30 comprises a setting guide 40. The setting guide 40 may have an inlet opening 42, an outlet opening 43, and a tubular section 41 extending therebetween. At least the tubular section 41 may have an inner cross-section which is non-circular. The setting guide 40 has a slot on a side facing an endless conveyor 77 to which a pusher 71 is mounted. The slot allows a support rod of the pusher 71 to extend therethrough, so that the pusher 71 and further pushers 72-75 may be advanced by rotation of the endless conveyor 77.

(33) The inlet opening 42 may be in communication with a cooling channel, allowing a pusher to move a spring from a receptacle of the cooling channel into the setting guide 40. The inlet opening 42 may have a shape tapering towards the tubular section 41 to facilitate transfer of springs from the cooling channel to the setting guide 40.

(34) The outlet opening 43 may be located at a plate 60. The outlet opening 43 may be flush with a surface of the plate 60 which faces an abutment member 50. The outlet opening 43 has a shape which allows the pusher 71 to move therethrough.

(35) The spring setting device 30 comprises an abutment member 50. The abutment member 50 comprise an abutment surface 51 against which a spring may be compressed by the pusher 71 to set the spring.

(36) The abutment member 50 may comprise at least one further abutment surface 52, 53.

(37) The abutment member 50 comprises a recess 54. The recess 54 is dimensioned to allow the pusher 71 to pass therethrough.

(38) The abutment member 50 may comprise at least one further recess 55, 56. Each further recess of the at least one further recess 55, 56 is dimensioned to allow the pusher 71 to pass therethrough.

(39) The abutment member 50 may be movably mounted. The abutment member 50 may be mounted such that, alternatingly, an abutment surface 51, 52, 53 and a recess 54, 55, 56 can be positioned so as to face the outlet opening 43 of the setting guide 40. The abutment member 50 may be configured such that it can be displaced, e.g. rotated, between a position in which an abutment surface 51, 52, 53 is positioned in an overlapping relationship with a pusher 71 in the setting guide 40 and another position in which the abutment member 50 is positioned in a non-overlapping relationship with the pusher 71 in the setting guide 40, so as to allow the pusher 71 to be moved through one of the recesses 54, 55, 56.

(40) The abutment member 50 may be rotatably mounted. A rotation axis 59 of the abutment member 50 may extend parallel to the longitudinal axis of the setting guide 40.

(41) The abutment member 50 may be configured to transport a spring compressed against the abutment member 50 by the pusher 71 in a direction which is transverse to the longitudinal axis of the setting guide 40. The abutment member 50 may be configured to slide a compressed spring along the plate 60, retaining it in a compressed state between the abutment member 50 and the plate 60. The abutment member 50 may engage the spring in a force fit and/or in a form fit to transport it away from the outlet opening 43 and towards a discharge position 64 at which the spring is discharged from the abutment member 50. The abutment member 50 may comprise at least one projection 57 which engages the spring in a form fit to transport it away from the outlet opening 43 and towards the discharge position 64. A projection 57 may be provided on each one of the abutment surfaces 51, 52, 53.

(42) The plate 60 may comprise a ledge 61 to assist in guiding the spring.

(43) A discharge mechanism may comprise a discharge pusher 65. The discharge mechanism may be configured to discharge the spring from the abutment member 50. To this end, the discharge pusher 54 may be displaceably supported on the plate 60 to eject the spring at the discharge position 64. The discharge pusher 65 may be displaceable along a guide feature 66, e.g. a guide slot, on the plate 60.

(44) While an abutment member 50 having a propeller shape with a plurality of slats radiating out from a center of the propeller shape is illustrated in FIG. 2, abutment members having other shapes may also be used. Further, while a rotatably mounted abutment member 50 is shown in FIG. 2, the abutment member 50 may be mounted for translatory displacement. The rotatably mounted abutment member 50 does not need to perform full rotations about the rotation axis, although such a configuration may offer further advantages in terms of cycle times.

(45) The spring setting device 30 comprises a pusher 71. The pusher 71 is operative to compress a spring against the abutment member 50. The pusher 71 may be operative to convey the spring from a receptacle of the cooling channel into the setting tube 40 before compressing it.

(46) The spring setting device 30 may comprise at least one further pusher 72-75. Each pusher of the at least one further pusher 72-75 may be configured to compress a spring against the abutment member 50. Each pusher of the at least one further pusher 72-75 may be configured to convey the spring from a receptacle of the cooling channel into the setting tube 40 before compressing it.

(47) The plurality of pushers 71-75 of the spring setting device may respectively be configured to pass through each one of the receptacles 54, 55, 56 formed on the abutment member. This allows the pushers 71-75 to be moved past the abutment member 50 for a return movement to the inlet opening 41, with the return movement not requiring a reciprocating motion of any pusher 71-75 within the setting guide 40.

(48) The pusher 71 and, if present, the at least one further pusher 72-75 may be mounted to a carrier. Each pusher 71-75 may respectively be mounted to the endless conveyor 77 via a mount 76. The mount 76 may be attached to the endless conveyor 77 and may comprise a rod dimensioned to position the pusher within the setting guide 40 when pusher is advanced towards the abutment member 50.

(49) The carrier may be an endless conveyor 77. The endless conveyor 77 may be an endless belt or may comprise a plurality of endless chains. The endless conveyor 77 may be offset from the setting guide 40. The endless conveyor 77 has a length along the setting guide 40 which is defined by a distance between rotation axes of deflection rollers 78, 79 around which the endless conveyor 77 is wound. The length of the endless conveyor 77 along the longitudinal axis of the setting guide 40 may be greater than the length of the setting guide 40 plus a height of an uncompressed spring which is to be set.

(50) A pusher mechanism 70 which comprises one or several pushers 71-75 may comprise additional components. For illustration, a pusher guide structure may comprise at least on pusher guide member 81, 82. A pair of pusher guide members 81, 82 may be provided to guide the pushers 71-75 therebetween. Guide features 83 are provided for engagement with mating guide features of the pusher mounts 76. For illustration, a guide projection on the pusher mount may be displaceably received in a mating guide recess 83 of the pusher guide structure. The pusher guide structure may guide the pusher 71-75 at least when the pusher is displaced towards the abutment member 50, i.e., when the pusher 71-75 is respectively located so as to project downwardly from the conveyor belt 70.

(51) The spring setting device 30 is configured in such a way that the pusher 71 and the at least one further pusher 72-75 do not need to perform a reciprocating movement in the setting guide 40. Rather, the endless conveyor 77 of the spring setting station may be rotated without reversal of the direction of rotation. The endless conveyor 77 may be rotated in one direction only. As will be explained in more detail with reference to FIG. 3 to FIG. 13, the pusher drive and the abutment member drive are operated in a coordinated manner such that, after having compressed a spring against the abutment member, the pusher may continue moving in the same direction of motion until it has passed the plane in which the abutment member extends. The pusher is returned to the inlet opening 42 while it is not located within the setting guide 40.

(52) FIG. 3 shows a front view of the spring setting device 30, the drawing plane extending perpendicularly to the longitudinal axis of the setting guide 40. FIG. 4 shows a partial broken away longitudinal view, with the longitudinal axis of the setting guide 40 extending in the drawing plane. In the operational state shown in FIG. 3 and FIG. 4, the abutment member 50 is positioned in a non-overlapping relationship with the pusher 71 which just completed compression of a spring 91 against the abutment member 50. The abutment member 50 is positioned such that a recess 54 is arranged at the outlet opening 43 of the setting guide 40 to allow the pusher 71 to move past the abutment member 50.

(53) The outlet opening 43 of the spring guide 40 is flush with the surface of the plate 60 which faces the abutment member 50. The outlet opening 43 may be surrounded by the plate 60 so as to prevent formation of gaps between the outlet opening 43 and the surface of the plate 60 which faces the abutment member 50. An insert 62 may be provided in the plate 60 to define a recess shaped to match the inner cross-section of the setting guide 40.

(54) In order to compress a spring 91, the pusher 71 may be positioned such that it is flush with the surface of the plate 60 which faces the abutment member 50. After compression of the spring 91, the abutment member 90 is rotated by a pre-defined angle. The pre-defined angle may be equal to 360/(2.Math.N), with N being the number of different abutment surfaces 51-53 provided on the abutment member 50. Rotation of the abutment member 50 by the predefined angle displaces the compressed spring 91 away from the outlet opening 43 of the setting guide 40. The spring 91 is displaces along an annular channel 63 defined in between the plate 60 and the abutment member 50. Rotation of the abutment member 50 by the predefined angle, subsequent to compression of the spring 91, ensures that the abutment member 50 is positioned in a nonoverlapping relationship with the pusher 71 which compressed the spring 91. A recess 54 is positioned along the longitudinal axis of the setting guide 40, so that the outlet opening 43 of the setting guide 40 is kept clear of the abutment member when the abutment member 50 is rotated by the predefined angle after compression of the spring 91.

(55) As illustrated in FIG. 4, in this state of the setting station, the pusher 71 which compressed the spring 90 may be moved past the plane 99 in which the abutment member 50 extends. The pusher drive mechanism may be operated so as to advance the pusher 71 from the position in which it is flush with the surface of the plate 60 which faces the abutment member 50 to a position in which it passed the abutment member 50, allowing the pusher 71 to be returned to the inlet opening 42 of the setting guide along the opposite side of the endless conveyor 77.

(56) As illustrated in FIG. 3, a spring 90 compressed in a preceding operation cycle of the spring setting device 30 by a further pusher 75 may be retained on the abutment member 50 while the spring 91 is compressed by the pusher 71 against the abutment member 50. In the state illustrated in FIG. 3 in which the abutment member 50 was rotated by the predefined angle and the pusher 71 is moved out of the outlet opening 43 and past the abutment member 50, a discharge mechanism may be operated to discharge the spring 90 compressed in the preceding operation cycle. A discharge pusher 65 may be displaced relative to the plate 60. The discharge pusher 65 may be displaced along a radial direction of the abutment surface 53 on which the spring 90 compressed in the preceding operation cycle is retained. The discharge pusher 65 may complete a movement cycle which includes a discharge movement in a radially outward direction and a return movement while the abutment member 50 is kept stationary.

(57) In the spring setting device 30 according to embodiments, the endless conveyor 77 and the abutment member 50 may be actuated in an intermittent manner. The actuation may be implemented in such a manner that, at any given time in the operation cycle, at most one of the endless conveyor 77 and the abutment member 50 moves.

(58) The spring setting device 30 may be configured such that the endless conveyor 70 is advanced by a first distance and a second distance in an alternating manner. The endless conveyor 70 may be advanced by a first distance to cause the pusher 71 to compress a spring 91. At the end of this movement of the endless conveyor 70, the pusher 71 may be positioned so as to be flush with the outlet opening 43 of the setting guide 40. After rotation of the abutment member 50, the endless conveyor 70 may be advanced by a second distance to cause the pusher 71 to move past the abutment member, allowing the pusher 71 to be returned to the inlet opening 42 along the opposite side of the endless conveyor 70.

(59) FIG. 5 illustrates actuation of a pusher drive mechanism and of an abutment member drive mechanism of a spring setting device according to an embodiment. FIG. 5 shows the velocity 100 of the endless conveyor 77 to which the pusher(s) are attached. FIG. 5 illustrates the angular velocity 110 of the abutment member 50. FIG. 5 shows the movement during two operation cycles. While linearly increasing and decreasing velocity profiles are illustrated in FIG. 5, other velocity profiles may be implemented.

(60) A rotation 111 of the abutment member 50 displaces an abutment surface 51 away from the outlet opening 43 of the setting guide 40, so that the abutment member 50 is positioned in a non-overlapping relationship with the pusher 71 which compressed the spring 91. The spring 91 is thereby moved away from the outlet opening 43. A previously compressed spring 90 may be displaced further along the plate 60 towards the discharge position 64. The pusher 71 is kept stationary during the rotation 111 of the abutment member 50.

(61) A movement 101 of the endless conveyor 77 moves the pusher 71 which compressed the spring 91 past the abutment member 50. The abutment member 50 may be kept stationary while the pusher 71 is displaced. The pusher 71 may be displaced by a second distance in the movement 101. The movement 101 may move the pusher 71 from a position at which it is flush with the outlet opening 43 to a position in which it moved past the abutment member 50 and can return to the inlet opening 42 along the opposite side of the endless conveyor 77. The pusher 71 may be moved through the recess 54 in the abutment member 50.

(62) A further rotation 112 of the abutment member 50 positions a further abutment surface 52 along the longitudinal axis of the setting guide 40. The further abutment surface 52 may be positioned so as to face the outlet opening 43. The further rotation 112 may displace the spring 91 which was previously compressed by the pusher 71 further towards the discharge position 64 at which it will be discharged from the abutment member 50. The endless conveyor 77 may be kept stationary during the further rotation 112. The further rotation 112 may rotate the abutment member 50 by the same predefined angle as the preceding rotation 111.

(63) A movement 102 of the endless conveyor 77 moves a further pusher 72 so that it advances a further spring 92 towards the abutment member 50. The pusher 72 compresses the further spring 92 on the further abutment surface 52. The pusher 71 which compressed the preceding spring 91 starts moving back towards the inlet opening 42 along the endless conveyor 77. A third pusher 73 may retrieve a third spring 93 from a receptacle of a cooling channel and may move it into the inlet opening 42 of the setting guide 40 in the movement 102 of the endless conveyor 77. The abutment member 50 may be kept stationary while the endless conveyor 77 performs the movement 102. In the movement 102, the endless conveyor 77 may move by a first distance. The first distance may be different from the second distance, thereby alternating the stroke of a pusher in consecutive displacements.

(64) A rotation 113 of the abutment member 50 displaces the further abutment surface 53 away from the outlet opening 43 of the setting guide 40, so that the abutment member 50 is positioned in a non-overlapping relationship with the pusher 72 which compressed the further spring 92. The further spring 92 is thereby moved away from the outlet opening 43. The spring 91 compressed by the pusher 71 is displaced further along the plate 60 until it becomes positioned at the discharge position 64. The further pusher 72 is kept stationary during the rotation 113 of the abutment member 50.

(65) A movement 103 of the endless conveyor 77 moves the further pusher 72 which compressed the further spring 92 past the abutment member 50. The abutment member 50 may be kept stationary while the further pusher 72 is displaced. The further pusher 72 may be displaced by the second distance in the movement 103. The movement 103 may move the further pusher 72 from a position at which it is flush with the outlet opening 43 to a position in which it moved past the abutment member 50 and can return to the inlet opening 42 along the opposite side of the endless conveyor 77. The further pusher 72 may be moved through the recess 55 in the abutment member 50. The pusher 71 continues its return movement to the inlet opening 50. A discharge mechanism may be operated to discharge the spring 90 from the abutment member 50.

(66) A further rotation 114 of the abutment member 50 positions a third abutment surface 53 along the longitudinal axis of the setting guide 40. The third abutment surface 53 may be positioned so as to face the outlet opening 43. The further rotation 114 may displace the further spring 92 which was previously compressed by the further pusher 72 further towards the discharge position 64 at which it will be discharged from the abutment member 50. The endless conveyor 77 may be kept stationary during the further rotation 114. The further rotation 114 may rotate the abutment member 50 by the same predefined angle as the preceding rotations 111-113.

(67) A movement 104 of the endless conveyor 77 moves the third pusher 73 so that it advances the third spring 93 towards the abutment member 50. The third pusher 73 compresses the third spring 93 on the third abutment surface 53. The pusher 71 and the further pusher 72 continue moving back towards the inlet opening 42 along the endless conveyor 77. A fourth pusher 94 may retrieve a fourth spring from a receptacle of a cooling channel and may move it into the inlet opening 42 of the setting guide 40 in the movement 104 of the endless conveyor 77. The abutment member 50 may be kept stationary while the endless conveyor 77 performs the movement 104. In the movement 104, the endless conveyor 77 may move by the first distance. The first distance may be different from the second distance, thereby alternating the stroke of a pusher in consecutive displacements.

(68) The operation cycles may be repeated. It will be appreciated that different ones of the abutment surfaces 51-53 will be consecutively positioned in front of the outlet opening 43 for compression of a spring. Different pushers 71-75 will consecutively displace an associated spring along the setting guide 40 and compress the associated spring against the abutment surface which is positioned at the outlet opening 43. The pushers 71-75 will respectively be moved past different recesses 54-56 of the abutment member 50 for initiating a return movement towards the inlet opening 42.

(69) With reference to FIG. 6 to FIG. 11, operation of the spring setting device 30 will be described in more detail. FIGS. 6A, 7A, 8A, 9A, 10A, and 11A respectively show a partially broken away view of the spring setting device, with a viewing direction perpendicular to the longitudinal axis of the setting guide 40. FIGS. 6B, 7B, 8B, 9B, 10B, and 11B respectively show a front view of the spring setting device, with a viewing direction along the longitudinal axis of the setting guide 40.

(70) While a spring setting device is illustrated in which the abutment member 50 comprises three abutment surfaces 51-53 and three recesses 54-56, other abutment member configurations may be used. While a spring setting device is illustrated in which five pushers 71-75 are attached to the endless conveyor 77, other numbers of pushers may be used.

(71) FIG. 6A and FIG. 6B show the spring setting device 30 in a configuration in which a pusher 71 compressed a spring 91 against the abutment surface 51 to set the spring 91. A further pusher 72 engages an end of a further spring 92 which it pushed out of a receptacle of a cooling channel and into the setting guide 40. The spring 91 is held in compression by the pusher 71 and the abutment surface 51.

(72) In order to effect compression of the spring 91 by the pusher 71, the endless conveyor 77 is advanced by a first distance. This causes the further pusher 72 to push a further spring 92 from a receptacle of a cooling channel into the setting guide 40.

(73) FIG. 7A and FIG. 7B show the spring setting device 30 in a first operational phase of an operation cycle. The first operational state starts in a configuration in which the spring 91 is held in compression in between the pusher 71 and an abutment surface 51 of the abutment member. In the first operational state, the abutment member 50 may be displaced in a direction transverse to the longitudinal axis of the setting guide 40. In the first operational state, the abutment member 50 may be rotated by a first predefined angle about a rotation axis which is parallel to the longitudinal axis of the setting guide 40.

(74) In the first operational phase, the displacement of the abutment member 50, e.g. by rotation of the abutment member 50, displaces the compressed spring 91 away from the outlet opening 43 of the setting guide 40 in a direction transverse to the longitudinal axis of the setting guide 40. The spring 91 is held in compression in between the abutment member 50 and the plate 60. A projection 57 on the abutment surface 51 may assist in engaging the spring 91 in a form fit to move it away from the outlet opening 43 and along the plate 60.

(75) In the first operational phase, the displacement of the abutment member 50 results in an arrangement in which the abutment member 50 is positioned in a non-overlapping relationship with the pusher 71 which is located at the outlet opening 43 of the setting tube 40. The recess 54 may be positioned along the longitudinal axis of the setting tube 40, providing a clearance for the pusher 71 to pass therethrough.

(76) FIG. 8A and FIG. 8B show the spring setting device 30 in a second operational phase of an operation cycle, which is subsequent to the first operational phase illustrated in FIG. 7A and FIG. 7B.

(77) The second operational state starts in a configuration in which the pusher 71 which compressed the spring 91 is positioned at the outlet opening 43 of the setting guide 40. The spring 91 is held in compression in between the abutment surface 51 of the abutment member 50 and the plate 60. The spring 91 is offset from the outlet opening 43 to allow the pusher 71 to be passed therethrough.

(78) In the second operational phase, a displacement 132 of the pusher 71 is effected. The endless conveyor 77 may move by a second distance. The second distance is greater than a distance between the abutment member 50 and the outlet opening 43. The second distance may be different from the first distance.

(79) During the second operational phase, the discharge mechanism may optionally be operated to discharge a previously compressed spring 90 from the abutment member 50. For illustration, a spring 90 which was compressed in the operation cycle preceding the operation cycle in which the spring 91 was compressed may be held at a discharge position 64 in between the third abutment surface 53 and the plate 60. Linear or pivoting displacement of the discharge pusher 65 may push the spring 90 out of the receptacle defined in between the third abutment surface 53 and the plate 60. The discharge pusher 65 may perform a discharge movement 141. A separate actuator may be provided to actuate the discharge pusher 65.

(80) The discharged spring 90 may be inserted into a tube of pocket material, for example, or may be further processed otherwise.

(81) During the second operational phase, the abutment member 50 may be kept stationary.

(82) FIG. 9A and FIG. 9B show the spring setting device 30 in an operational phase in which the discharge pusher 65 undergoes a return movement 142 to its rest position. The operational phase illustrated in FIG. 9A and FIG. 9B may also be integrated in the second operational phase illustrated in FIG. 8A and FIG. 8B or in the third operational phase illustrated in FIG. 10A and FIG. 10B.

(83) FIG. 10A and FIG. 10B show the spring setting device 30 in a third operational phase of an operation cycle, which is subsequent to the second operational phase illustrated in FIG. 8A and FIG. 8B. The third operational phase starts in a state in which the pusher 71 has already been moved past the abutment member 50 and the abutment member 50 keeps the outlet opening 43 of the setting tube clear.

(84) In the third operational phase, a further rotation 122 of the abutment member 50 positions a further abutment surface 52 along the longitudinal axis of the setting guide 40. The further abutment surface 52 may be positioned so as to face the outlet opening 43. The further rotation 122 may displace the spring 91 which was previously compressed by the pusher 71 further towards the discharge position 64 at which it will be discharged from the abutment member 50. The endless conveyor 77 may be kept stationary during the further rotation 122. The further rotation 122 may rotate the abutment member 50 by the same predefined angle as the preceding rotation 121.

(85) The third operational phase brings the spring setting device to a state in which a further abutment surface 52 is positioned so as to face the outlet opening 43, thereby allowing the further spring 92 to be compressed in between the further pusher 72 and the further abutment surface 52.

(86) FIG. 11A and FIG. 11B show the spring setting device 30 in a fourth operational phase of an operation cycle, which is subsequent to the third operational phase illustrated in FIG. 10A and FIG. 10B. The fourth operational phase starts in a state in which a further abutment surface 52 is positioned so as to face the outlet opening 43, thereby allowing the further spring 92 to be compressed in between the further pusher 72 and the further abutment surface 52.

(87) In the fourth operational phase, the further pusher 72 may be moved along the setting guide by a first distance. The movement 134 of the further pusher 72 may be effected by advancing the endless conveyor 77 by the first distance. The first distance may be different from the second distance.

(88) Advancing the endless conveyor 77 by the first distance also moves all other pushers 71 and 73-75 mounted to the endless conveyor 77. The first pusher 71 may start travelling back to an initial position. The return movement of the first pusher 71 takes place while the first pusher 71 is removed from the setting guide 40. The first pusher 71 may be offset from the setting guide 40 while it travels back to its initial position for another spring compression cycle. The pusher 71 and the further pusher 72 mounted adjacent to the pusher 71 on the endless conveyor 77 may move in opposite directions in at least a fraction of the fourth operational phase.

(89) In the fourth operational phase, the spring 91 is maintained in compression in between the abutment surface 51 and the plate 60. At the end of the fourth operational phase, the further spring 92 is maintained in compression in between the further pusher 72 and the further abutment surface 52.

(90) The various operational phases may now be repeated in cycles, thereby completing a plurality of operation cycles which each sets a spring.

(91) FIG. 12 is a flow chart of a method 150 according to an embodiment. The method 150 may be performed by the spring setting device 30 or the apparatus 1 according to an embodiment.

(92) At 151, a pusher 71 is advanced to compress a spring 91 against an abutment member 50. The abutment member 50 may be movably mounted, in particular rotatably mounted. The pusher 71 may be mounted to an endless belt 77 or other endless conveyor. The pusher 71 may be advanced in the setting guide 40 which provides stability to the spring 91 during compression, mitigating the risk that the spring deflects in a radial direction upon compression. The abutment member 50 may be kept stationary while the pusher 71 compresses the spring 91. The endless conveyor 77 may be advanced by a first distance to cause the pusher 71 to compress the spring 91.

(93) At 152, the abutment member 50 is displaced. The abutment member 50 may be rotated by a predefined angle. Rotation of the abutment member 50 may transport the compressed spring away from an outlet opening 43 of the setting guide. Rotation of the abutment member 50 may cause the abutment member 50 to be positioned in a non-overlapping relationship with the pusher 71 which compressed the spring 91. A recess 54-56 of the abutment member 50 may be positioned at the outlet opening 43 at the end of the rotation.

(94) At 153, the pusher 71 may be advanced by a second distance. The pusher 71 may move through the recess of the abutment member, so as to move past the plane in which the abutment member 50 extends. The abutment member 50 may be kept stationary while the pusher 71 is moved past the abutment member 50, to allow the pusher 71 to return to its initial position for a new operation cycle. The second distance may be smaller than the first distance. The second distance may be greater than a distance between the abutment member 50 and the outlet opening 43.

(95) At 154, the abutment member 50 is displaced. The abutment member 50 may be rotated by the predefined angle. Rotation of the abutment member 50 may transport the compressed spring further away from the outlet opening 43 of the setting guide 40. Rotation of the abutment member 50 may cause a further abutment surface 52 of the abutment member 50 to be positioned in an overlapping relationship with the outlet opening 43. The spring setting device is now prepared for compression of the next spring in the next operation cycle. To this end, the method may return to 151.

(96) FIG. 13 is a flow chart of a method 155 according to an embodiment. The method 155 may be performed by the spring setting device 30 or the apparatus 1 according to an embodiment.

(97) In the method 155, a discharge mechanism may be actuated at 156 to discharge a spring retained between the abutment member 50 and the plate 60. The discharge mechanism may be actuated while the pusher is concurrently moved from the outlet opening 43 of the setting tube 40 past the abutment member 50.

(98) It will be appreciated that, in the devices, apparatuses, and methods according to embodiments, each pusher may respectively compress a spring against a different one of the abutment surface 51-53 in consecutive operation cycles. Each pusher may respectively move through a different one of the recesses 54-56 in consecutive operation cycles.

(99) While embodiments of the invention have been described with reference to the drawings, a wide variety of modifications may be implemented in other embodiments. For illustration, the discharge mechanism does not need to be implemented by a discharge pusher which is configured for translatory or pivoting displacement. For illustration, a recess in the plate in may cause the compressed spring to disengage from the abutment member under the action of gravity.

(100) While embodiments have been described in which the abutment member comprises three abutment surfaces which are respectively separated by recesses, different numbers of abutment surfaces and recesses may be implemented. While embodiments have been described in which five pushers are mounted to an endless conveyor, different numbers of pushers may be used. While embodiments have been described in which the pusher mount may have guide projections which may be received in a continuous guide track, in other embodiments, the guide projections of the pusher mounts may be received in a guide track only while the pusher slides along the setting guide.

(101) While embodiments have been described in the context of an apparatus for producing a string of pocket springs, the embodiments are not limited thereto. For illustration, the spring setting device may be provided as a separate apparatus which may be combined with a spring former apparatus and further downstream processing. For further illustration, the spring setting device and method may be used to set springs for unpocketed innerspring units.

(102) The spring setting device, apparatus, and method according to embodiments of the invention may be used for manufacturing innerspring units for mattresses, sofas, armchairs, or other bedding or seating furniture, without being limited thereto.