弹簧植绒流水线是专为各类弹簧（如汽车电尾门弹簧、座椅调节弹簧、家电减震弹簧等）设计的自动化表面处理设备，核心功能是通过静电植绒或机械植绒工艺，在弹簧表面均匀附着一层短纤维绒毛层（常用材质为尼龙、涤纶、粘胶纤维），起到减噪、减震、防刮擦、防腐蚀的作用，同时提升弹簧的外观质感与使用舒适度，是弹簧产品功能升级与品质提升的关键加工设备。

该流水线实现全流程自动化作业，典型工作流程包含六大核心环节：

1. 自动上料与定位：通过振动送料机或机械臂，将待加工弹簧批量输送至输送链带，设备搭载分拣机构，可自动规整弹簧姿态（如立式、卧式），确保后续植绒均匀；针对异形弹簧，还可配备专用夹具，避免加工过程中移位。

2. 预处理清洁：弹簧依次经过脱脂槽（采用中性脱脂剂，去除表面冲压油污、防锈油及指纹）、水洗槽（两道纯水洗，清除残留脱脂剂）、烘干炉（温度 80-100℃，热风循环烘干，去除表面水分），确保弹簧表面洁净干燥，为绒毛附着提供良好基底。

3. 底胶喷涂：清洁后的弹簧进入喷涂室，由自动喷枪均匀喷涂一层专用植绒底胶（如丙烯酸酯胶、聚氨酯胶），底胶厚度可通过喷枪压力与输送速度精准控制（通常为 5-15μm），确保胶层无漏喷、流挂。

4. 植绒处理：根据弹簧材质与使用需求，选择静电植绒或机械植绒工艺：

• 静电植绒：弹簧进入静电植绒室，短纤维在高压静电场（电压 30-80kV）作用下带电，定向吸附于涂有底胶的弹簧表面，绒毛排列整齐，附着力强；

• 机械植绒：通过高速旋转的毛刷或气流喷射，将短纤维均匀压覆在弹簧底胶表面，适用于绒毛较长（≥0.5mm）或弹簧结构复杂的场景。

5. 烘干固化：植绒后的弹簧进入固化炉，分阶段控温（第一阶段 60-80℃预固化，第二阶段 120-150℃完全固化），固化时间 15-30 分钟，使底胶充分交联，确保绒毛与弹簧表面牢固结合，剥离强度≥5N/25mm（行业标准）。

6. 后处理与下料：固化后的弹簧先经过冷风冷却，再进入刷毛机构，去除表面浮绒；随后由视觉检测模块检查植绒均匀度与漏点，合格弹簧自动输送至下料区，不合格品标记剔除，完成整个加工流程。

该流水线的核心优势体现在四方面：

• 植绒质量稳定：自动化控制底胶厚度、植绒密度（通常为 30-80 根 /mm²）、固化参数，绒毛覆盖率达 99% 以上，无漏植、秃点，满足不同场景对弹簧植绒的精度要求；

• 兼容性强：可适配直径 3-50mm、长度 10-300mm 的各类弹簧（圆柱弹簧、异形弹簧、扭转弹簧等），通过更换夹具与调整工艺参数，快速切换产品型号，适配多品种小批量或大批量生产；

• 生产效率高：单条流水线每小时可处理 800-2000 件弹簧，支持 24 小时连续作业，相比传统手工植绒效率提升 10-15 倍，大幅降低人工成本；

• 环保合规：采用水溶性环保底胶，VOCs 排放量≤20mg/m³；烘干固化产生的废气经活性炭吸附 + UV 光解处理后达标排放；浮绒通过集尘系统回收，避免粉尘污染，符合国家环保标准。

目前，该流水线广泛应用于汽车零部件（电尾门弹簧、座椅弹簧、减震弹簧）、家电（洗衣机减震弹簧、空调风扇弹簧）、家具（沙发弹簧、床垫弹簧）等领域，为弹簧产品提供功能性与装饰性兼具的表面处理解决方案。

The Spring Flocking Production Line is an automated surface treatment equipment specially designed for various springs (such as electric tailgate springs, seat adjustment springs, home appliance shock absorption springs, etc.). Its core function is to uniformly attach a layer of short-fiber flocking layer (common materials: nylon, polyester, viscose fiber) on the spring surface through electrostatic flocking or mechanical flocking processes. This layer provides noise reduction, shock absorption, scratch resistance, and corrosion resistance, while improving the spring’s appearance texture and usage comfort. It is a key processing equipment for functional upgrading and quality improvement of spring products.

This production line realizes full-process automated operation, with a typical working process including six core links:

1. Automatic Loading and Positioning: Springs to be processed are batch-transported to the conveyor chain via a vibratory feeder or robotic arm. The equipment is equipped with a sorting mechanism that can automatically arrange the spring posture (e.g., vertical, horizontal) to ensure uniform subsequent flocking. For special-shaped springs, dedicated fixtures can also be equipped to prevent displacement during processing.

2. Pretreatment Cleaning: Springs sequentially pass through a degreasing tank (using neutral degreaser to remove stamping oil, anti-rust oil, and fingerprints from the surface), water washing tanks (two stages of pure water washing to remove residual degreaser), and a drying oven (temperature 80-100℃, hot air circulation drying to remove surface moisture). This ensures the spring surface is clean and dry, providing a good base for flocking adhesion.

3. Base Adhesive Spraying: Cleaned springs enter the spraying chamber, where an automatic spray gun uniformly sprays a layer of special flocking base adhesive (e.g., acrylic adhesive, polyurethane adhesive). The base adhesive thickness can be precisely controlled via spray gun pressure and conveyor speed (usually 5-15μm), ensuring no missing spraying or sagging of the adhesive layer.

4. Flocking Treatment: Electrostatic flocking or mechanical flocking is selected based on the spring material and application requirements:

• Electrostatic Flocking: Springs enter the electrostatic flocking chamber. Short fibers are charged under a high-voltage electrostatic field (30-80kV), directionally adsorbing to the spring surface coated with base adhesive. The fibers are neatly arranged with strong adhesion.

• Mechanical Flocking: Short fibers are uniformly pressed onto the spring’s base adhesive surface via a high-speed rotating brush or air jet. This is suitable for scenarios with longer fibers (≥0.5mm) or complex spring structures.

5. Drying and Curing: Flocked springs enter the curing oven, with staged temperature control (first stage 60-80℃ pre-curing, second stage 120-150℃ full curing) and a curing time of 15-30 minutes. This allows the base adhesive to fully cross-link, ensuring firm bonding between fibers and the spring surface, with a peel strength ≥5N/25mm (industry standard).

6. Post-treatment and Unloading: Cured springs are first cooled by cold air, then enter a bristle brushing mechanism to remove surface loose fibers. A visual inspection module then checks flocking uniformity and missing points. Qualified springs are automatically transported to the unloading area, while unqualified products are marked and rejected, completing the entire processing flow.

The core advantages of this production line are reflected in four aspects:

• Stable Flocking Quality: Automated control of base adhesive thickness, flocking density (usually 30-80 fibers/mm²), and curing parameters ensures a flocking coverage rate of over 99%, with no missing flocking or bald spots, meeting the precision requirements for spring flocking in different scenarios.

• Strong Compatibility: It can adapt to various springs with diameters of 3-50mm and lengths of 10-300mm (cylindrical springs, special-shaped springs, torsion springs, etc.). By replacing fixtures and adjusting process parameters, it can quickly switch product models, adapting to small-batch multi-variety or mass production.

• High Production Efficiency: A single production line can process 800-2000 springs per hour and supports 24-hour continuous operation. Compared with traditional manual flocking, efficiency is increased by 10-15 times, significantly reducing labor costs.

• Environmental Compliance: It uses water-based environmentally friendly base adhesive, with VOCs emissions ≤20mg/m³; waste gas from drying and curing is discharged up to standard after activated carbon adsorption + UV photolysis treatment; loose fibers are recovered via a dust collection system to avoid dust pollution, complying with national environmental standards.

Currently, this production line is widely used in automotive components (electric tailgate springs, seat springs, shock absorption springs), home appliances (washing machine shock absorption springs, air conditioner fan springs), and furniture (sofa springs, mattress springs) fields, providing surface treatment solutions that combine functionality and decoration for spring products.