Machine and method for assembling a bedding foundation

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.