Machine and method for assembling a bedding foundation

Abstract

An apparatus for assembling a bedding foundation having a grid formed from rows of spring modules and a frame to support the grid may include a first portion including a sensing system configured to determine a size of the frame, a second portion including a stapling assembly having a plurality of staplers and a wire gripper coupled to each of the staplers, and a third portion configured to receive the bedding foundation and advance the bedding foundation relative to the first portion and the second portion.

What is claimed is: 
     
         1 . An apparatus for assembling a bedding foundation having a grid formed from rows of spring modules and a frame to support the grid, the apparatus comprising:
 a first portion including a sensing system configured to determine a size of the frame;   a second portion including a stapling assembly having a plurality of staplers and a wire gripper coupled to each of the staplers; and   a third portion configured to receive the bedding foundation and advance the bedding foundation relative to the first portion and the second portion.   
     
     
         2 . The apparatus of  claim 1 , wherein the sensing system includes an optical sensor. 
     
     
         3 . The apparatus of  claim 1 , wherein each wire gripper includes:
 a grip housing that defines a pair of cam slots;   a first grip plate and a second grip plate supported in the grip housing, the first grip plate and the second grip plate each including a first portion and a second portion, the second portion including a tab extending from the second portion;   a first cam pin coupled to the first grip plate and a second cam pin coupled to the second grip plate, the first cam pin and the second cam pin disposed in the cam slots; and   a spring supported in the grip housing that engages the first grip plate and the second grip plate and biases the first grip plate and the second grip plate in a first direction;   wherein the first grip plate and the second grip plate are slidable relative to the grip housing in the first direction in response to engagement with the frame and slidable relative to each other in a second direction in response to movement of the first cam pin and the second cam pin in the cam slots.   
     
     
         4 . The apparatus of  claim 3 , wherein each slot includes a first portion that extends downwardly in a substantially vertical direction and a second portion that extends inwardly at an angle relative to vertical. 
     
     
         5 . The apparatus of  claim 4 , wherein the second portion extends inwardly at an approximately thirteen-degree angle. 
     
     
         6 . The apparatus of  claim 3 , wherein the grip housing, the first grip plate, and the second grip plate are electrically isolated from an associated stapler of the plurality of staplers. 
     
     
         7 . The apparatus of  claim 1 , wherein the plurality of staplers descends at a first pressure and a second pressure higher than the first pressure. 
     
     
         8 . The apparatus of  claim 1 , further comprising a monitoring system configured to determine whether the apparatus is operating properly, the apparatus monitoring system including a staple advancement system, a stapler descent sensor, and a carriage advancement system. 
     
     
         9 . The apparatus of  claim 8 , wherein the staple advancement system includes a positional sensor configured to measure a position of a staple carriage pusher. 
     
     
         10 . The apparatus of  claim 8 , wherein the stapler descent sensor measures a displacement of the stapler. 
     
     
         11 . The apparatus of  claim 8 , wherein the carriage advancement system includes a grid detection sensor and a frame detection sensor. 
     
     
         12 . The apparatus of  claim 11 , wherein the grid detection sensor is a ground detection sensor. 
     
     
         13 . The apparatus of  claim 11 , wherein the frame detection sensor is a detent sensor. 
     
     
         14 . The apparatus of  claim 8  further comprising a frame measurement system configured to measure a size of the frame and wherein the staplers are longitudinally positioned based on the size of the frame. 
     
     
         15 . The apparatus of  claim 14 , wherein the frame measurement system includes at least one optical sensor. 
     
     
         16 . A method of assembling a bedding foundation having a grid formed from rows of spring modules and a frame to support the grid, the method comprising:
 operating a plurality of staplers at a first pressure;   determining whether any faults occurred; and   operating the plurality of staplers at a second pressure that is higher than the first pressure.   
     
     
         17 . The method of  claim 16 , further comprises monitoring staple advancement. 
     
     
         18 . An apparatus for assembling a bedding foundation having a grid formed from rows of spring modules and a frame to support the grid, the apparatus comprising:
 a first section;   a second section coupled to the first section, and   a third section configured to receive and advance the bedding foundation relative to the first section and the second section, the third section including:   a carriage supporting a foundation gripper assembly, and   a foundation sensing assembly coupled to the foundation gripper assembly and configured to determine a position of the frame and a position of the grid.   
     
     
         19 . The apparatus of  claim 18 , wherein the foundation sensing assembly includes a detent sensor configured to determine the frame is present. 
     
     
         20 . The apparatus of  claim 18 , wherein the foundation sensing assembly includes a ground detect sensor configured to determine the grid is present.