弹簧喷胶喷毛流水线是弹簧表面功能性处理的自动化设备，核心是通过 “喷胶 + 喷毛” 两道关键工序，在弹簧表面形成均匀的纤维附着层（常用尼龙、涤纶短纤维），起到减噪、防刮擦、提升手感的作用，尤其适配结构复杂、需精准控制纤维覆盖的弹簧（如汽车精密弹簧、家电减震弹簧），是弹簧产品从 “基础功能” 向 “高品质体验” 升级的重要加工设备。
该流水线实现喷胶与喷毛的协同自动化，典型工作流程包含五大核心环节：
自动上料与姿态校准：通过伺服输送系统将待加工弹簧（直径 2-40mm、长度 8-250mm）精准输送至工位，搭载视觉定位模块，自动校正弹簧角度（如扭转弹簧的扭转方向、异形弹簧的凸起朝向），确保喷胶喷毛无死角；针对小型弹簧，还可配备多工位转盘，提升批量处理效率。
预处理活化：弹簧先经过低温除油区（40-60℃中性除油剂喷淋，去除表面油污与指纹），再通过热风干燥（温度 70-90℃），最后经等离子处理机活化表面 —— 通过等离子体轰击弹簧表面，增强胶层附着力，解决传统工艺中 “胶层易脱落” 的问题。
精准喷胶：预处理后的弹簧进入密闭喷胶室，采用多轴联动喷枪（可根据弹簧形状自动调整喷射角度），喷涂专用弹性底胶（如改性丙烯酸胶、橡胶型胶）；胶层厚度通过喷枪压力（0.3-0.6MPa）与输送速度（0.5-2m/min）精准控制，通常为 8-20μm，且支持局部喷胶（如弹簧两端受力点可加厚胶层）。
同步喷毛：喷胶后的弹簧无需等待，直接进入喷毛室，通过高压气流喷毛装置（气流压力 0.5-0.8MPa）将短纤维（长度 0.3-1mm）均匀喷射至胶层表面；喷毛室内置纤维回收通道，未附着的纤维经筛选后可循环使用，纤维利用率达 90% 以上；同时配备纤维密度监测仪，实时调整喷毛量（30-70 根 /mm²），避免纤维堆积或漏喷。
固化定型与后处理：完成喷毛的弹簧进入分段固化炉（第一阶段 80-100℃胶层初固，第二阶段 130-150℃纤维与胶层交联固化），固化时间 12-25 分钟，确保纤维剥离强度≥4N/25mm；固化后经冷风冷却至常温，再通过柔性毛刷机构去除表面浮毛，最后由尺寸检测模块检查弹簧外径（避免喷毛后尺寸超差），合格产品自动下料，不合格品标记分流。
该流水线的核心优势体现在三方面：
工艺协同性强：喷胶与喷毛工位间距仅 0.5-1m，实现 “胶层未干即喷毛”，大幅提升纤维附着力，相比 “喷胶后静置再喷毛” 的传统工艺，剥离强度提升 30% 以上；且喷胶、喷毛参数可联动调整（如胶层加厚时自动增加喷毛量），避免工艺脱节。
适配性灵活：可处理圆柱弹簧、扭转弹簧、异形弹簧等多种类型，通过更换喷枪喷头（如扇形喷头用于平面、锥形喷头用于凹槽）与调整喷毛气流角度，轻松适配弹簧复杂结构；支持单条流水线同时处理 2-3 种规格弹簧（如汽车座椅弹簧与门锁弹簧），切换时间≤10 分钟。
成本与环保平衡：采用水溶性底胶（VOCs 排放量≤15mg/m³），喷毛室纤维回收率达 90% 以上，减少原材料浪费；自动化程度达 95%，单条流水线仅需 1-2 人监控，相比手工喷毛（需 4-6 人 / 线），人工成本降低 60% 以上，且产品合格率稳定在 98% 以上。
目前，该流水线广泛应用于汽车零部件（如汽车门锁弹簧、悬架辅助弹簧）、智能家居（如扫地机器人减震弹簧、智能马桶盖升降弹簧）、精密仪器（如医疗器械弹簧、电子设备缓冲弹簧）等领域，为对 “静音”“手感” 有高要求的场景提供定制化表面处理方案。
The Spring Gluing and Fiber Spraying Line is an automated equipment for functional surface treatment of springs. Its core lies in forming a uniform fiber-attached layer (common materials: nylon, polyester short fibers) on the spring surface through two key processes—"gluing + fiber spraying". This layer provides noise reduction, scratch resistance, and improved hand feel, and is especially suitable for springs with complex structures that require precise fiber coverage control (such as automotive precision springs, home appliance shock absorption springs). It is an important processing equipment for upgrading spring products from "basic functions" to "high-quality experience".
This production line realizes the collaborative automation of gluing and fiber spraying, with a typical working process including five core links:
Automatic Loading and Posture Calibration: Springs to be processed (diameter 2-40mm, length 8-250mm) are accurately transported to the workstation via a servo conveying system. Equipped with a visual positioning module, it automatically corrects the spring angle (such as the torsion direction of torsion springs, the convex orientation of special-shaped springs) to ensure no dead corners in gluing and fiber spraying; for small springs, a multi-station turntable can also be equipped to improve batch processing efficiency.
Pretreatment Activation: Springs first pass through a low-temperature degreasing area (40-60℃ neutral degreaser spraying to remove surface oil and fingerprints), then undergo hot air drying (temperature 70-90℃), and finally are surface-activated by a plasma processor—plasma bombards the spring surface to enhance the adhesion of the adhesive layer, solving the problem of "easy adhesive layer peeling" in traditional processes.
Precision Gluing: The pretreated springs enter a closed gluing chamber, where a multi-axis linked spray gun (which can automatically adjust the spray angle according to the spring shape) sprays a special elastic base adhesive (such as modified acrylic adhesive, rubber-type adhesive); the adhesive layer thickness is precisely controlled by spray gun pressure (0.3-0.6MPa) and conveying speed (0.5-2m/min), usually 8-20μm, and local gluing is supported (such as thickening the adhesive layer at the stress points at both ends of the spring).
Synchronous Fiber Spraying: Immediately after gluing, the springs enter the fiber spraying chamber without waiting. A high-pressure air flow fiber spraying device (air pressure 0.5-0.8MPa) sprays short fibers (length 0.3-1mm) evenly onto the surface of the adhesive layer; the fiber spraying chamber has a built-in fiber recovery channel, and unused fibers can be recycled after screening, with a fiber utilization rate of over 90%; at the same time, a fiber density monitor is equipped to adjust the fiber spraying amount (30-70 fibers/mm²) in real time to avoid fiber accumulation or missing spraying.
Curing Shaping and Post-treatment: The fiber-sprayed springs enter a staged curing oven (first stage 80-100℃ for initial adhesive curing, second stage 130-150℃ for cross-linking curing of fibers and adhesive layer), with a curing time of 12-25 minutes to ensure the fiber peel strength is ≥4N/25mm; after curing, they are cooled to room temperature by cold air, then surface loose fibers are removed by a flexible brush mechanism, and finally a dimension detection module checks the spring outer diameter (to avoid dimension deviation after fiber spraying). Qualified products are automatically unloaded, and unqualified products are marked for diversion.
The core advantages of this production line are reflected in three aspects:
Strong Process Synergy: The distance between the gluing and fiber spraying stations is only 0.5-1m, realizing "fiber spraying before the adhesive layer dries", which greatly improves fiber adhesion. Compared with the traditional process of "gluing, standing, then fiber spraying", the peel strength is increased by more than 30%; and the gluing and fiber spraying parameters can be adjusted in linkage (such as automatically increasing the fiber spraying amount when the adhesive layer is thickened) to avoid process disconnection.
Flexible Adaptability: It can handle various types of springs such as cylindrical springs, torsion springs, and special-shaped springs. By replacing the spray gun nozzles (such as fan nozzles for flat surfaces, conical nozzles for grooves) and adjusting the fiber spraying air flow angle, it can easily adapt to complex spring structures; it supports simultaneous processing of 2-3 types of springs on a single production line (such as automotive seat springs and door lock springs), with a switching time of ≤10 minutes.
Balance of Cost and Environmental Protection: It uses water-based base adhesive (VOCs emission ≤15mg/m³), and the fiber recovery rate in the fiber spraying chamber is over 90%, reducing raw material waste; the automation degree reaches 95%, and only 1-2 people are needed to monitor a single production line. Compared with manual fiber spraying (requiring 4-6 people per line), the labor cost is reduced by more than 60%, and the product qualification rate is stably above 98%.
Currently, this production line is widely used in automotive components (such as automotive door lock springs, suspension auxiliary springs), smart home (such as sweeping robot shock absorption springs, smart toilet lid lifting springs), and precision instruments (such as medical device springs, electronic equipment buffer springs) fields, providing customized surface treatment solutions for scenarios with high requirements for "silence" and "hand feel".