Machine and method for assembling a bedding foundation

Patent metadata

Field	Value
Publication number	US-11304535-B2
Application number	US-201815994718-A
Country	US
Kind code	B2
Filing date	May 31, 2018
Priority date	May 31, 2018
Publication date	Apr 19, 2022
Grant date	Apr 19, 2022

Abstract

An apparatus for assembling a bedding foundation having spring modules and a frame includes a support configured to receive the frame, a bridge disposed over the support, and staplers movably coupled to the bridge and positioned over the support, each stapler configured to staple a spring module to the frame. The apparatus also includes cameras coupled to the bridge and positioned over the support. Each stapler is operatively associated with one of the cameras and each camera is positioned to provide a field of view toward the support. The apparatus also includes a driver configured to move the frame relative to the support and a controller in communication with the cameras and the driver, the controller configured to receive vision guidance signals from one of the cameras to direct movement of the driver and of the stapler operatively associated with the one of the cameras.

First claim

What is claimed is:

1. An apparatus for assembling a bedding foundation having a grid formed from rows of spring modules, each row of spring modules extending between a first side of the grid and a second side of the grid opposite the first side and having a plurality of spring modules positioned between the first side and the second side of the grid, and a frame to support the grid, the apparatus comprising:
a stationary horizontal support configured to receive the frame, the horizontal support having a length defining a lengthwise direction and a width;
a stationary bridge spaced over the stationary horizontal support and spanning at least partially across the width;
a bank of staplers configured to staple each spring module of the plurality of spring modules in each row of spring modules of the grid to a bottom portion of the frame, each stapler in the bank of staplers movably coupled to the stationary bridge and positioned over the stationary horizontal support, wherein each stapler in the bank of staplers is configured to staple a bottom portion of a respective spring module of the plurality of spring modules in each row or spring modules of the grid to the frame, wherein each stapler in the bank of staplers is further configured to move in a linear vertical direction relative to the stationary horizontal support independently of each of the other staplers in the bank of staplers and to pivot in the lengthwise direction independently of each of the other staplers in the bank of staplers and the staplers are movably coupled to the stationary bridge to adjust a spacing therebetween in a direction across the width of the stationary horizontal support;
actuators coupled to the stationary bridge, wherein each stapler in the bank of staplers is operated by one of the actuators to pivot in the lengthwise direction;
wherein the stationary horizontal support includes a stationary load table positioned on a first side of the stationary bridge and configured to receive the grid and frame, and a carriage table positioned on a second side of the stationary bridge opposite the first side and configured for removal of the grid and frame as stapled together by the bank of staplers; and
a carriage movably disposed relative to the carriage table and configured to move the frame relative to the stationary bridge and the stationary horizontal support in the lengthwise direction underneath the stationary bridge from the stationary load table to the carriage table for stapling of the grid to the frame by the bank of staplers.

2. The apparatus of claim 1 , further comprising cameras coupled and fixed in position relative to the stationary bridge, each stapler operatively associated with one of the cameras, wherein each camera is positioned to provide a field of view toward the stationary horizontal support.

3. The apparatus of claim 2 , further comprising a controller in communication with each of the cameras, the controller configured to receive vision guidance signals from at least one of the cameras to adjust the spacing between each of the staplers in the bank of staplers in the direction along the width of the stationary horizontal support, adjust the movement of select staplers in the bank of staplers in the linear vertical direction relative to the stationary horizontal support, and adjust the pivoting of select staplers in the bank of staplers in the lengthwise direction.

4. The apparatus of claim 3 , wherein the controller is configured to receive vision guidance signals from at least one of the cameras to direct the movement of the carriage.

5. The apparatus of claim 4 , wherein the controller is configured to issue a first command to adjust the spacing between each of the staplers in the bank of staplers in a direction along the width of the stationary horizontal support in response to a first vision guidance signal, to issue a second command to move the carriage, to issue a third command to stop movement of the carriage in response to a second vision guidance signal, and to issue a fourth command to move at least some of the staplers in the bank of staplers in the linear vertical direction relative to the stationary horizontal support in response to a third vision guidance signal.

6. The apparatus of claim 1 , wherein each stapler of the bank of staplers is movably mounted on a vertical track that is pivotally coupled to the stationary bridge.

7. The apparatus of claim 1 , wherein each stapler in the bank of staplers is coupled to a common linkage that is configured to extend in a direction across the width of the support to increase the distance between each of the staplers in the bank of staplers and to retract in a direction across the width of the support to decrease the distance between each of the staplers in the bank of staplers.

8. The apparatus of claim 1 , further comprising a controller configured to issue a command to pivot at least one of the staplers in the bank of staplers in response to a vision guidance signal.

9. The apparatus of claim 1 , wherein each stapler in the bank of staplers is pivotable in the lengthwise direction while moving in the linear vertical direction.

10. An apparatus for assembling a bedding foundation having a grid formed from rows of spring modules, each row of spring modules having a plurality of spring modules positioned between a first end and a second end of the row, and a frame to support the grid, the apparatus comprising:
a stationary support configured to receive the frame, the stationary support having a length defining a lengthwise direction and a width;
a stationary bridge spaced over the stationary support and spanning at least partially across the width; and
a bank of staplers configured to staple each spring module of the plurality of spring modules in each row of spring modules of the grid to a bottom portion of the frame, each stapler in the bank of staplers movably coupled to the stationary bridge, each stapler of the bank of staplers configured to staple a respective spring module of the plurality of spring modules in each row of spring modules of the grid to the frame, and
wherein each stapler in the bank of staplers is further configured to move in a linear vertical direction relative to the stationary support independently of each of the other staplers in the bank of staplers and to pivot relative to the stationary support in the lengthwise direction, and
wherein at least two staplers in the bank of staplers are movably coupled to the stationary bridge to adjust a spacing therebetween in a direction across the width of the stationary support, and
wherein the stationary support includes a stationary load table positioned on a first side of the stationary bridge and configured to receive the grid and frame, and a carriage table positioned on a second side of the stationary bridge opposite the first side and configured for removal of the grid and frame as stapled together by the bank of staplers; and
a carriage movably disposed relative to the stationary support and configured to move the frame relative to the stationary bridge and the stationary support in the lengthwise direction underneath the stationary bridge from the stationary load table to the carriage table for stapling of the grid to the frame by the bank of staplers.

11. The apparatus of claim 10 , further comprising cameras coupled and fixed in position relative to the stationary bridge, each stapler operatively associated with one of the cameras, wherein each camera is positioned to provide a field of view toward the stationary support.

12. The apparatus of claim 11 , further comprising a controller in communication with each of the cameras, the controller configured

Assignees

• L&P Property Man Co

Inventors

• Myers Jefferson W
• Brummett Travis L
• Carrier Joshua A
• Mccune Richard L
• Rawlings Franklin H

Classifications

• B27F7/006

  Nailing or stapling machines provided with means for operating on discrete points · CPC title

• A47C23/02

  using leaf springs, e.g. metal strips (wooden springs A47C23/06) · CPC title

• B21F33/04

  Connecting ends of helical springs for mattresses · CPC title

• B21F33/025

  Mounting of mattress innersprings on borderframes · CPC title

• B27F7/003

  Nailing or stapling machines provided with assembling means · CPC title