MATTRESS SCAN

MATTRESS INSPECTION SYSTEMS

Gridbots MattressSCAN is a perfect combination of technologies which utilises Robotics + AI + Machine Vision together to solve a complex problem: consistent, objective, 100% end-of-line quality inspection of mattresses.

The system can scan multiple sides (Top + Bottom + All 4 Sides) for fabric defects and can also measure the dimensions of the mattress including height. The system generates a 3D profile along with 2D camera based images.

The system utilises a high speed GPU based compute mechanism to analyse the images in real time.

The scanning of each mattress can be completed within 10 seconds.

MATTRESS INSPECTION SYSTEM

≤ 10 s

Cycle time per mattress

Sides inspected

0.1 mm

Scanning resolution

1000

User-defined recipes

Features

Precision Servo Conveyors

0.1 MM Scanning Resolution

Bed Size:[Length: 8 Meters / Width: 3 Meters ]

4 Cameras system

Automatic Accept / Reject Signalling

Barcode / QR Based Traceability

Auto Learn Feature

Programmable Speed of Scanning

Fabric+Width+Height Data at multiple points

Fast ROI and High Speed Operation

Image Archive of Every Mattress Scanned

Shift / Batch Wise Quality Reports

How It Works

Each mattress passes through a fully automatic, four-stage inspection sequence. No operator judgement is involved in the accept / reject decision, so every mattress is held to the same standard on every shift.

STEP 01

Load & Identify

Mattress enters on the servo conveyor. Barcode / QR is read and the matching recipe (size, fabric, tolerances) is loaded automatically.

STEP 03

AI Analysis

GPU-accelerated deep learning models classify fabric defects while the 3D point cloud is compared against the recipe tolerances.

STEP 02

Scan

Laser profilometer captures the 3D profile (length, width, height, crown, edge straightness) while 2D cameras image the top, bottom and all four sides.

STEP 04

Decide & Record

Pass / Fail signal is sent to the line, defects are marked on the HMI with images, and the result is logged against the serial number.

Specifications

General
Model Series	GB-MV-MI/2000
Mattress Size Supported	LxBxH [2500x2000x400 mm]
Inspection Bed Size	8 m (L) x 3 m (W)
Surfaces Inspected	Top + Bottom + 4 Sides
Cycle Time	Upto 10 Seconds
Mattress Types	Pocket / Bonnell Spring, PU Foam, Memory Foam, Latex, Coir, Hybrid
Vision & Measurement
Camera Count and Types	Laser Profilometer + 2D Stereo Camera (4 Camera System)
Scanning Resolution	0.1 mm
Linear Motion Resolution	1 mm
Height Measurement Resolution	1 mm
Data Captured	Fabric image + Length + Width + Height at multiple points + 3D profile
Compute	Industrial PC with GPU for real time AI inference
Motion & Control
Conveyor	Precision Servo Conveyor, programmable speed
Motion Controller	gridMOVE
User Defined Recipes	Upto 1000 Supported
Operator Interface	Touch screen HMI with live defect overlay
Line Interface	Digital I/O for Pass / Fail / Reject; Ethernet for data export
Electrical & Environment
Power Rating	500 Watts
Power Consumption	Less Than 500W
Supply	230 V AC, 1 Phase, 50 Hz
Operating Temperature	0 – 45 °C
Compressed Air	Not Required

Defect Detection Capability

MattressSCAN combines 2D AI inspection for surface defects with 3D laser profiling for geometric defects. The defect library is extendable through the Auto Learn feature using your own good / bad samples.

Defect Category	Examples	Detection Method	Surfaces
Fabric Defects	Holes, cuts, tears, snags, pulled threads	2D AI Vision	All 6
Stains & Contamination	Oil / grease marks, dirt, glue spots	2D AI Vision	All 6
Stitching Defects	Open seams, skipped stitches, loose threads, wavy quilting	2D AI Vision	Top, Bottom, Sides
Tape Edge Defects	Tape edge misalignment, open / puckered tape	2D + 3D	4 Sides
Label & Branding	Missing, skewed or wrong label	2D AI Vision	Configurable
Dimensional Defects	Out of tolerance length, width, height	3D Laser Profile	Full body
Shape Defects	Uneven height, crown / dip, bulges, non-square corners	3D Laser Profile	Top, Sides

Performance

Inspection Time per Mattress (seconds)

Full 6-side inspection including dimension check.

Detection Rate by Defect Category (%)

Manual figures reflect typical visual inspection at line speed.

Mattresses Inspected per 8-Hour Shift

Manual inspection throughput falls as fatigue builds through the shift.

Cycle Time Breakdown (10 s)

AI analysis runs in parallel with conveyor motion.

Manual Inspection vs MattressSCAN

Parameter	Manual Inspection	Gridbots MattressSCAN
Time per mattress (6 sides + dimensions)	60 – 90 s	≤ 10 s
Bottom surface inspection	Requires flipping, often skipped	Automatic, every mattress
Height measurement	Tape, 1–3 points	Laser, full 3D profile
Consistency across shifts	Depends on operator & fatigue	Same standard 24 x 7
Image record of each mattress	✗ No	✓ Yes, linked to serial no.
Defect trend analytics	✗ Manual logbook	✓ Automatic reports
Customer complaint traceability	✗ Limited	✓ Full image + dimension history
Inspectors required per shift	2 – 3	0 (1 operator supervises)

Dimensional Measurement

Measurement	Range	Resolution	Method
Length	Upto 2500 mm	1 mm	Servo encoder + laser edge detection
Width	Upto 2000 mm	1 mm	Laser profile
Height (multi-point)	Upto 400 mm	1 mm	Laser profile
Corner squareness	—	0.5°	3D point cloud
Surface flatness / crown	—	1 mm	3D point cloud

Return on Investment

The savings come from three places: fewer inspectors per shift, fewer defective mattresses reaching customers, and faster resolution of complaints using the stored image record.

Benefit	Typical Impact
Inspection labour	Upto 70% reduction
Defects escaping to customer	Upto 80% reduction
Warranty / return claims	Significant reduction
Line throughput	Inspection no longer the bottleneck
Typical payback	12 – 18 months

Cumulative Savings vs Investment

Indicative, for a 2-shift plant. Actual payback depends on volume and labour cost.

Software & Integration

Live Defect Overlay on HMI

Recipe Management by SKU / Size

Adjustable Tolerance & Severity Thresholds

User Levels: Operator / Supervisor / Admin

PDF / Excel Shift & Batch Reports

Defect Pareto & Trend Dashboards

Data Export to ERP / MES

Remote Support & Model Updates

Scope of Supply

Item	Standard	Optional
Inspection frame with servo conveyors	✓
Laser profilometer + 2D camera set with lighting	✓
GPU industrial PC with MattressSCAN software	✓
Touch HMI and control panel (gridMOVE)	✓
Installation, commissioning & operator training	✓
Barcode / QR scanner		✓
Automatic reject / diverter conveyor		✓
ERP / MES integration		✓
Annual maintenance contract		✓

Frequently Asked Questions

Can it handle different mattress sizes on the same line?	Yes. Each size / SKU is stored as a recipe (upto 1000) and is selected automatically by barcode or manually from the HMI.
How is the bottom surface inspected without flipping?	The conveyor design gives the cameras a view of the underside as the mattress passes, so no flipping or handling is needed.
How does the system learn our defects?	With the Auto Learn feature, your quality team marks good and defective samples; the AI model is trained on them and deployed on the system.
Can it be added to an existing production line?	Yes. It sits at end of line before packing and connects to existing conveyors via digital I/O.
What happens to a rejected mattress?	The system flags it on the HMI with marked defect images, signals the line, and optionally diverts it to a reject conveyor.
Is support available after installation?	Yes. Gridbots provides on-site and remote support from India, with periodic AI model updates.

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