Machine and method for assembling a bedding foundation

An apparatus for assembling a bedding foundation having spring modules and a frame, the apparatus comprising:

• a support configured to receive the frame;
• a bridge disposed over the support;
• staplers movably coupled to the bridge and positioned over the support, each stapler configured to staple a spring module to the frame;
• cameras coupled to the bridge and positioned over the support, wherein each stapler is operatively associated with one of the cameras and each camera is positioned to provide a field of view toward the support;
• 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.

A method of using a vision guided control system having a camera system and a controller to assemble a bedding foundation comprising a grid formed from rows of spring modules and a frame to support the grid, the method comprising:

• placing the frame on a horizontal support having a length and a width;
• placing the grid of spring modules on the frame;
• adjusting a spacing of select staplers within an overhead bank of staplers, the spacing in a direction across the width of the horizontal support in response to a visual guidance signal sent from the camera system to the controller;
• commanding a carriage to move the frame in a direction along the length of the horizontal support;
• stopping movement of the carriage to align a row of spring modules beneath the overhead bank of staplers in response to visual guidance signals sent from the camera system to the controller when the camera system identifies a predetermined number of spring modules in the row of spring modules as being aligned beneath the overhead bank of staplers;
• and
• using the camera system to direct stapling movement of select staplers in the bank of staplers to attach the grid to the frame.

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 support configured to receive the frame, the support having a length defining a lengthwise direction and a width;
• a bridge spaced over the support and spanning at least partially across the width;
• and
• a bank of staplers, each stapler in the bank of staplers movably coupled to the bridge, each stapler of the bank of staplers configured to staple a spring module 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 support independently of each of the other staplers in the bank of staplers and to pivot relative to the support in the lengthwise direction, and
• wherein at least two staplers in the bank of staplers are movably coupled to the bridge to adjust a spacing therebetween in a direction across the width of the support.