Automatic miter machine

Abstract

An apparatus for mitering portions of a workpiece to create mitered corners. The apparatus includes a base assembly. An X-Y positioning table is coupled to the base assembly. Clamp assemblies are coupled to the top of the positioning table for holding portions of a workpiece in place on the positioning table. A sewing machine is coupled to the base assembly and is adapted to sew a series of stitches along a V-shaped path. A notching device is coupled to the base assembly downstream from the sewing machine and is adapted for removing a portion of a workpiece defined by the V-shaped stitching path.

1 . An apparatus for mitering portions of a workpiece to create mitered corners, the apparatus comprising:
 a base assembly;   an X-Y positioning table coupled to the base assembly;   at least two clamp assemblies coupled to the top of the positioning table for holding portions of a workpiece in place on the positioning table;   a sewing machine coupled to the base assembly and positioned adjacent the positioning table, the sewing machine being adapted to sew a series of lock stitches along a V-shaped path at the desired location of the miter in the workpiece; and   a notching device positioned downstream from the sewing machine for removing a triangular-shaped portion of a workpiece, defined by the V-shaped stitching path, to create a mitered corner.   
   
   
       2 . The apparatus of  claim 1 , wherein the workpiece comprises a portion of folded gusset material. 
   
   
       3 . The apparatus of  claim 2 , wherein the workpiece further comprises a portion of a flange piece secured to the portion of folded gusset material. 
   
   
       4 . The apparatus of  claim 3 , wherein the workpiece further comprises a portion of a border material attached to the portion of folded gusset material. 
   
   
       5 . The apparatus of  claim 1 , wherein the sewing machine is further adapted to sew a back tack at the beginning of the V-shaped path. 
   
   
       6 . The apparatus of  claim 1 , further comprising a disposal device for removing the triangular-shaped portion of the workpiece from the notching device. 
   
   
       7 . The apparatus of  claim 1 , further comprising a controlling computer for synchronizing operation of the positioning table, the sewing device, and the notching device. 
   
   
       8 . The apparatus of  claim 1 , wherein the clamp assemblies are adjustable for accommodating materials of differing thicknesses. 
   
   
       9 . The apparatus of  claim 7 , wherein the operation of the positioning table is achieved by using an electric motor coupled to the positioning table, the electric motor being adapted to cause the positioning table to move along a programmed operation path. 
   
   
       10 . The apparatus of  claim 7 , wherein the controlling computer receives user input from at least one foot pedal. 
   
   
       11 . A machine for creating mitered corners of a pillow-top mattress gusset, the machine comprising:
 a base;   a work surface coupled to the base, the surface having at least two sewing clamps disposed thereon, wherein the work surface is operable to be moved in each of two perpendicular directions, and wherein each of the sewing clamps has a V-shaped profile;   a sewing device positioned adjacent the work surface, the sewing device having a controlling computer, wherein the sewing device is programmed to create a series of stitches along an outside edge of the V-shaped profile of each of the sewing clamps;   a cutting device comprising a triangular shear for cutting a triangular-shaped portion out of a gusset assembly piece, the cutting device positioned downstream from the sewing device such that the shear is operable to remove the portion adjacent the sewn, V-shaped profile;   a disposal device for removing the triangular-shaped portion of the gusset assembly piece from the cutting device; and   at least one controlling computer for synchronizing operation of the work surface, the sewing device, the cutting device, and the disposal device.   
   
   
       12 . The machine of  claim 11 , wherein the disposal device comprises a vacuum system having a hose coupled to a lower portion of the cutting device at one end and a disposal container at the other end. 
   
   
       13 . The machine of  claim 11 , wherein synchronizing operation comprises automating a multi-stage process. 
   
   
       14 . The machine of  claim 13 , wherein the multi-stage process comprises at least two stages. 
   
   
       15 . The machine of  claim 14 , wherein the multi-stage process comprises four stages. 
   
   
       16 . A multiple-stage system for automatically sewing and notching portions of a gusset to create a pillow-top mattress gusset having mitered corners, the system comprising:
 a clamping component disposed on an X-Y table, wherein the clamping component comprises at least two clamp devices, each clamp device having a V-shaped profile;   a sewing component for sewing a series of stitches along the V-shaped profile of each of the clamp devices;   a notching component for removing a triangular-shaped portion of a gusset; and   a controlling computer for automating a multiple-stage mitering process, wherein a stage comprises:
 positioning a clamp device adjacent to the sewing component, wherein a portion of a gusset is secured by the clamp device; 
 sewing a series of stitches in the secured portion of the gusset along a V-shaped path; 
 repositioning the clamp device adjacent to the notching component; 
 cutting a triangular-shaped portion from the secured portion of the gusset, wherein the series of stitches remains intact; and 
 removing the triangular-shaped portion from the secured portion of the gusset. 
   
   
   
       17 . The system of  claim 16 , wherein sewing a series of stitches in the secured portion of the gusset comprises first sewing a back tack stitch in the first portion of the V-shaped path. 
   
   
       18 . The system of  claim 16 , wherein repositioning the clamp device adjacent to the notching component further comprises positioning a second clamp device adjacent to the sewing component. 
   
   
       19 . The system of  claim 18 , further comprising sewing a series of stitches in a second secured portion of the gusset along a V-shaped path defined by the V-shaped profile of the second clamp device. 
   
   
       20 . The system of  claim 19 , wherein a stage further comprises sewing a series of stitches in a second secured portion of the gusset simultaneous to cutting a triangular-shaped portion from a first secured portion of the gusset.