Summary:

Automation to Industry can brings quality, accuracy and precision to industrial processes from the simplest to the most complex. Industries like Foam Mattress manufacturers, to sustain in the market they have to produce according to the market needs. Manual process may not succeed day to day production need. To achieve the target (i.e., market demand) Automation is the process for increasing the Production rate, reducing the Cost and maintenance cost is also reduced.

Solution:

To increase the production, we need to upgrade the plant into Automation Plant. Stitching machine are used in this industry. This stitching machine is used to stitch the mattresses at equal level and maintain the unique distance while stitching. By this machine’s we can avoid the manual operations. Now coming to point where stitching a mattress by using a machine will get a perfect and accurate stitching & maintaining the quality in production.

Operation of the machine: In this machine we have used variable frequency drive and Sensors. The variable frequency drive is used to control the stitching speed automatically & controlling the speed at corners due to curvature shape in mattresses. And to achieve speed control automatically at corners of mattress, we used limit switch as a sensing input to the Variable Frequency Drive. With input provided by Limit Switches, a program is written in VFD to reduce the Speed of the machine at the corners to eliminates the improper stitching and gives well finished stitching at corners also & to maintain the quality of the mattress.