Vtc 100 Automatic Bonnell Transfer Machine

VK Matters Machinery

For the past 55 years, VK Mattress Machinery
has been consistently providing the mattress
and furniture industry with high-quality solutions
and tools to help producers all over the world
elevate their production quality and efficiency.
Today, one of our most advanced machines on
the market is the VTC Series - Automatic Bonnell
Transfer Machine, which was developed with the
aspiration to provide a robust machine

 

that not only can serve you for many years but can
also immensely impact your bonnell production in
ways that no other machine on the market can, while
achieving the highest-level of production efficiency
in the world.

 

Worldwide
Presence
The VTC Automatic Bonnell Transfer Machine has a
worldwide presence, companies in Europe, Asia, Africa,
South America and North America are all using VTC
machines daily in order to provide their markets with
top-class bonnell spring mattresses and furniture.

 

The foundation of the company started when Mr. Veysel Kütüklü came back from
Germany, bringing with him 8 years worth of professional experience.
With that he officially founded VK Mattress Machinery on the 22nd of October 1968
in Bayrampasa, Istanbul, and started with the production of automotive parts for the
largest automotive factory in Turkey.
During the 1970s, VK started working with big international pharmaceutical
companies such as Pfizer, Hoechst, Novartis, Bayer, Schering, Knoll, Merck, Abdi
Ibrahim and many more to providing them high precision molds for medicine
packing. The extreme precision in the pharma industry with the acceptance of the
tolerance helped a lot to reach in a short time the highest quality level in the
mattress machinery industry.
Using all that experience from previous projects, and because of the extreme
demands on the market, VK ventured into the mattress and furniture industry with
the goal of providing the market with quality and top-notch machinery. It quickly
became one of the best machinery providers locally and internationally, and one of
only 3 companies in the world that can produce a fully automatic bonnell transfer
machine.

 

Production Made Easy

x Phase 1:
The steel wire gets formed to a
spring in the coiling machine.
x Phase 2:
The springs are getting knotted at
both ends.
x Phase 3:
The springs are getting heat treat-
ed between two electrodes.
x Phase 4:
The springs are getting transferred
to the assembly part of the machine.
x Phase 5:
Spring pusher system moves the
springs into the jaws.
x Phase 6:
A spiral wire assembles the springs
to get a finished & read-to-use
spring unit.

 

Exceptional Quality

x Impressive Wire Cutting
System
Wire cutting system with durable carbide
cutting tools. These tools are made for
the highest quality performance during the
cutting process of millions of springs.
* Strongest Wire Feeding
Rollers
Designed using the strongest materials, our
wire feeding rollers are proudly made in-house
by our engineers to make sure they have a
long lasting lifetime & durability, up to 10x
more than normal wire feed rollers.

 

2 Minutes
& 20 Seconds
That's all it takes to produce one single size spring unit with
a size of 90x190 cm | 8x23 springs. It's 60 seconds faster than
the closest competitors.

 

Unparalleled
Performance
Our VTC machine performance is miles ahead of
the competition. Whether you are working with 6,
8 or 13 rows, the machine works at a maximum
speed from the start, with no deceleration or
declines.

 

The graph above showcase a test results done on different machines from different competitors
using different row settings with similar working conditions. The number of springs produced per
minute is very consistent on the VTC machine at 80 springs per minute.

 

Highest Productivity Machine On The Market

At VK, we thrive for consistency and high performance machine, that's the reason behind our
steady and stable production performance of our VTC machine. With 80 springs/min our
machine has the highest performance of any bonnell machine on the market, with an
unmatched consistency, suitable for 24h production.
 

 

Immense Production Efficienly

During an 8 hours production shift, the VTC machine is capable of producing around 218 single
size mattresses (8x24 springs | 90x190cm), averaging a production time of 1 single size mattress
every 2 minutes and 20 seconds, while the other machine takes a minimum of 3 minutes and 25
seconds to produce 1 single size mattress in the same size.

 

x Automatic Lubrication
System
The automatic lubrication system ensures a
periodic oiling of 20 points on the machine
with the option to set the desired time frame
for each lubrication through the touch-
screen display. The oil tank capacity for the
coiling section holds 3 liters, while the spiral
lubrication tank can hold 6 liters. There is no
more need for manual lubrication needed.

 

x Damage Protecting
Arm Security System
Our german technology torque limiter
ensures a safe working environment
by making sure the machine is stopped if
anything blocks the arms from moving.
This security system prevents
bigger damage to the arms.

 

 

Impressive Features

x Digital Heat Treatment System
Our heat treatment unit is one of the most advanced technologies on these type of machines, it
provides maximum durability to the bonnell springs and ensures that every spring is stress-
relieved and stregthened. The flexibile heat treatment unit offers a multi degree treatment
options, which is adjustable easily from our touchscreen display.
x Unique Gear System
A robust gear system where gears be easily adjusted and replaced without struggling with a
chain system like on other machines. The red markings on the gears are allowing you to replace
gears in the shortest time. We are also using only high quality materials, to ensure that our gear
system can stand tough against gear failure, wear and tear as well as lasting the longest from any
coiling system on the market.

 

Adjustable
Robust Base
The rigid construction of the VTC machines offer a
vibration-free production experience, as well as a leveling
system that allows an easy stabilization of the coiling
section for it to be adjusted to the right level with the
assembly section. The machine design also makes it
easy to change the coiling section position to adjust the
spring height.

 

* Easy-To-Adjust Machine Drums
The drums used on our VTC machine are robustly empowered with servo motors and allowing
an independent operation without getting power from the main motor. The new designed drum
system allows an easy spring diameter change without the need to adjust the cam unit setting.

 

Meticulous Accuracy

x Coiling Control Panel
The machine offers multiple control panels to
change the coiling settings, which is located
inside the coiling area. This panel enables to
make adjustments on the spring outside
diameter and spring height in the easiest way.
x Soundproofing & Ventilation
The coiler unit is equipped with soundproofing
panels that helps reduced the production
noise drastically as well as a sound-insulated
ventilation system that helps clear oil dust and
small wire particles which keeps the coiler
unit clean.
x Wire Inputs
Wire inputs positioning options for the
machine basket can be in 3 areas depending
on the desired position by the purchasing
company, either left, front, or the back of
the machine.
x Door Lock Safety System
Another safety feature that the VTC machine
offers is something that is being ignored on
other machines: Door Lock Safety System
that prevents the machine from working in
case the coiler unit door is open, only after
closing that the machine resumes it's work
without the need of any intervention from the
operator.
x Floor Leveling System
During the VTC machine installation the floor
leveling system helps us level the different
parts of the machine to ensure a very stable
and steady production performance.
x Basket Cage
Built using a woven wire mesh design which
offers an excellent security for the rotating
wire bundles during production.

 

x Security Lambs
Safety light system on the top of the
coiler unit that helps indicate the status
of the machine.
(Red = Not Working, Green= Working)

 

x Spring Stabilizer
During the spring forming process the
spring stabilizer provides a smooth and
stable bonnell spring forming process.

 

x Patented Transfer Technology
The patented transfer mechanism is an optional designed integration between the coiling and
the assembly part of the machine, which takes the machine speed to the highest level. The per-
fect synchronization between the coiling part and the assembly part enables the transfer
of 80 springs/min on time.

 

Next Level
Bonnell Spring
Production
Not only the coiling part of the machine that
enjoys many features but also the patented
transfer unit of the VTC machine comes with
many more technical innovations.

 

x Outstanding Spring
Turning System
Our spring turning system makes sure
that that the first jaw in the assembly area
is receiving a 180° turned bonnell
spring, which is the standard for
bonnell spring unit production.
x Heat Resistant Belt
One of the most important part of the
transfer unit are the conveyor belts, they
are responsible of transferring the bonnell
springs produced in the coiling unit to the
transfer unit, for them to be assembled,
using a double layered, heat resistant belts
that can make sure this course of action is
done smoothly and efficiently, as well as
the added metal rollers that help tighten
the belt when they get loose.
x Spring Pusher System
Strong and sturdy spring pushers that pushes a row of springs into position to be assembled.
The spring pusher can be easily adjusted using the provided measuring tool.

 

* Easy Back-Door Access
Two back-doors gives the operator access into the spring pusher system to make easy adjust-
ments and changes in the easiest way to the spring unit sizes.

 

x Spring Conveyor Exit Door
Located on the end of the conveyor system of the
machine, the springs conveyor removal option
door acts as an exit for the defected/damaged
springs that shouldn't be transferred into the jaw
system, the springs go directly into a basket to be
collected and then be removed.

 

Flexibility
Like Never
Before
Knowing the huge challenge during the
production of different bonnell spring unit sizes,
we needed to make sure that the changeover
between all mattress sizes settings is done in a
seamless manner. To set the desired size for your
bonnell spring unit size you only need to change
the positioning of the jaw systems, which only
takes couple of minutes, which makes the VTC
machine revolutionary in term of size changes.
The VTC machine is benchmark in spring unit size
changes, sofa and mattress manufacturers are
switching between sizes daily without struggling
for many hours like on other machines.

 

x Push-Button Machine Opening System
The machine opening system stands on a robust gear system that can be opened or closed using
the main touchscreen of the machine. This machine design allows the best availability to make the
necessary changes on the assembly part of the machine, in the unlikely event of spiral problems,
the operator can quickly access this area and solve the issue on the machine, without the need to
open or push the machine manually.

 

x State-Of-The-Art
Height Adjustment System
The VTC machine offers the easiest system setting technology which can be adjusted
through the touchscreen display. This feature enables the adjustment of the spring height
automatically and accurately, without the need of any manual intervention.

 

İnspiring Teknology

20x Long-Lasting
& Sturdy Jaws
The VTC - Automatic Bonnell Transfer Machine comes
equipped with a standard 18 modular and long-lasting
jaws with the option of adding 7 more upon request to
make the maximum total of jaws that can be added
at 25 jaws.

 

x Stainless-Steel Spring
Unit Exit Table
Stainless steel spring unit exit table
where the fully finished spring unit lays
waiting to be collected. We made sure
to use a strong base and material that
lasts for many years ahead.

 

x Stainless-Steel Spring
Unit Exit Table
Stainless steel spring unit exit table
where the fully finished spring unit lays
waiting to be collected. We made sure
to use a strong base and material that
lasts for many years ahead.

 

x Spiral Encoder
The spiral encoder on the VTC machine gives you a very precise and accurate spiral wire
measurement.
x Assembly Slider Control Panel
Of the many control panels we have in the machine, the assembly control panel is located inside
the assembly area on a sliding mechanism that allows the use in any position of the machine,
whether you are on the left or the right end of the machine. The control panel can be reached
from any position for making adjustments on the spring unit sizes.

 

Switch/
Measure Mode
* Changing Spring Unit Sizes <10 sec
The switch and measure mode on the VTC machine
allows for an easy spring unit size change without the
need to move the sensor manually, it's all done under
10 seconds using the built-in touch screen display. Its
the easiest way to make spring unit size changes of
any machine on the market. This feature is exclusively
and only available on the VTC machine.

 

* Ingenious Spiral Knotting Options
With excellent spiral knotting options there is a possibility to change the firmness of the springs
units, the options are as follows:

The 4-5 knotting of the spiral wire allows to produce spring units with maximum firmness. This
system reduces the range of motion for the bonnell springs.

The 4-4 knotting of the spiral wire ensures the production of spring units with medium firmness.
This system allows a small degree of motion for the bonnell springs.
The working range of this knotting system is for springs in the diameter between 80-96mm and
wire diameter between 1.9-2.4mm. This option is suitable for roll-packing the spring units.

 

The 4-3 spiral wire knotting provides the production bonnell springs with maximum range of
motion. This knotting system is designed for mini bonnell springs in the diameter 70-78mm and
the wire diameter 1.9-2.2mm. This option offers the ideal solution to increase the number of
springs on bonnell spring units.

 

* Innovative Spiral Wire Lubrication
The automatic spiral wire lubrication makes sure the wire is continuously lubricated to avoid any
friction and allow a smooth motion throughout the whole bonnell spring unit assembly process.

 

x Precise Spiral Testing Tool
The spiral testing tool helps determine the pitch of the spiral wire and makes sure it's going
through the jaw system and the bonnell springs fluidly.

 

The VTC machine works non-stop in one of the largest european mattress
companies in Poland.
If you really care about efficiency, you need to examine down to the smallest
detail that a machine is suitable for 24 hours operation. With a VTC machine,
you can achieve this uninterrupted production and meet the demands of the industry.
Why should we evaluate only the first purchasing price of a machine that has been
used for many years instead of its performance?
Aren't we going to be producing everyday, non-stop with this machine?
The VTC machine is been designed with the highest quality raw materials and
components in accordance to meet the most difficult production conditions.
Are you ready to see the difference?

 

 

+3500 More Single Size Mattresses
Doing a quick calculation of the amount of potentially produced single size mattresses in a month results a +3500** more mattresses being produced by our VTC machine in mcomparison to other machines on the market.
80 springs x 60 minutes x 24 hours x 20 days

= 2.304.000 springs/184*
= 12.521 single size mattresses

 

 

Spring Type                         : Bonnell
Performance                        : 80 springs/min.
Production Capacity            : 38.400 springs/8 hours

                                             Approx. 210 Spring Units for Single Size Mattress/8 hours
                                             (90x190cm, 8x23 springs)
                                             Approx. 130 Spring Units for Double Size Mattress/8 hours
                                             (140x190cm, 13x23 springs)
Spring Outside Diameter      : 70 mm -96 mm

                                              Standard

                                              Ø 80-92 mm, Max. 18 Jaws, 1.9-2.4 mm
                                              Optional
                                              Ø 80-96 mm, Max. 18 Jaws, 1.9-2.4 mm
                                              Ø 70-78 mm, Max. 23 Jaws, 1.9-2.2 mm
                                              Ø 70-75 mm, Max. 25 Jaws, 1.9-2.2 mm
Spring Center Diameter       : 40 mm - 55 mm
Spring Height Diameter       : 75 mm - 180 mm
                                              Standard
                                             120 mm - 140 mm (5 turns)
                                             Optional
                                              75 mm - 120 mm (4 turns)
                                              140 mm - 160 mm (6 turns)

Spring Wire Diameter           :1.9 mm - 2.4 mm

Spiral Wire Diameter            : 1.3 mm - 1.4 mm
Working Width                      : 2000 mm
Power Consumption             : approx. 18 kW
Power Requirements            : Three Phase 380V
                                               Frequency: 50-60 Hz,
                                               Input Fuse: 63 A
                                               Cable: 4 x 10mm²
Working Temperature            : 0° C - 40° C
Weight                                   : approx. 4.800 kg
Wire Basket Capacity            : 1.000 kg
Spiral Wire Basket Capacity  : 2 x 850 kg
Control System                      : Mitsubishi Motion Control System