Belt Mechanism: A standard flat belt is chosen due to its high tensile strength, good preload retention, and low cost. The belt is installed on two rollers: one driving roller and one driven roller. The surface of the driving roller is patterned with a knurling process to increase friction and drive the belt. To prevent the belt from running off, guide rails are added on both sides. The belt has an internal support frame made of hollow steel welded as a skeleton, with a 2mm thick Q235 steel plate bent and placed on top to ensure the belt is evenly supported. The belt is mounted at an inclined angle to the feeding platform, with the right side lower than the left. The mattress enters the belt pre-pressing mechanism from the right and exits from the left, entering the rolling mattress machine main spindle for packaging. The belt inlet height is designed to be 270mm to accommodate mattresses with a height of 260mm or less.
Motor Drive Mechanism: To ensure the speed of the pre-pressing belt adjusts in real-time, a servo motor is used for driving. A worm gear reducer is selected to match the rolling speed, and a 10A chain is used to drive the active roller shaft of the belt through the reducer.
Encoder Mechanism: Since the pre-pressed mattresses are fed to the rolling mattress machine spindle, and the mattress roll gets larger as it is wrapped, the line speed increases as the diameter of the mattress roll increases. To ensure the mattress is compressed vertically and not tilted, the pre-pressing belt needs to adjust its speed in real-time to match the rolling speed of the rolling mattress machine. The encoder mechanism is added to ensure this by installing a follower roller shaft that floats and presses against the rolling spindle. As the spindle turns, the follower roller shaft follows at the same speed. An encoder is installed at one end of the follower roller shaft to read the speed in real-time, which then adjusts the speed of the servo motor via the PLC, ensuring the pre-pressing belt's speed matches the rolling speed of the rolling mattress machine.
