FIELD
The present disclosure relates to an assembly machine and method, and more particularly to a machine and method for assembling a bedding foundation.
BACKGROUND
Bedding foundations including a frame and a wire grid require multiple staples across and along the wire grid to couple the wire grid to the foundation. A foundation size corresponds to a mattress size (e.g., twin, full, queen, king, California king, etc.) and a foundation manufacturer frequently assembles foundation assemblies to correspond to multiple mattress sizes.
SUMMARY
The present disclosure provides, in one aspect, 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 including: a first portion including a sensing system configured to determine a size of the frame; a second portion including a stapling assembly having a bank 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 and second sections.
The present disclosure provides, in one aspect, 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 including: a stapler assembly including a plurality of staplers, and an apparatus 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.
The present disclosure provides, in one aspect, 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 including: operating the plurality of staplers down at a first pressure; determining whether any faults occurred; operating the plurality of staplers down at a second pressure that is higher than the first pressure.
The present disclosure provides, in one aspect, an apparatus for assembling a bedding foundation having a grid formed from rows of spring modules and a frame assembly to support the grid, the apparatus including: 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 and second sections, 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 wire grid.
Other features and aspects of the disclosure will become apparent by consideration of the following detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a machine for assembling a bedding foundation according to an embodiment of the present disclosure.
FIG. 2 is a perspective view of an exemplary embodiment of a foundation that may be assembled by the machine of FIG. 1.
FIG. 3 is a perspective view of an exemplary embodiment of an enclosure of the machine of FIG. 1.
FIG. 4 is a perspective view of an infeed table assembly of the machine of FIG. 1.
FIG. 5 is a perspective view of a portion of the infeed table assembly of FIG. 4.
FIG. 6 is a perspective view of a portion of the infeed table assembly of FIG. 4.
FIG. 7 is a perspective view of a bridge section of the machine of FIG. 1.
FIG. 8 is a perspective view of a portion of the bridge section of FIG. 7.
FIG. 9 is a front view of a stapler support assembly of the machine of FIG. 1, illustrated in a lowered position.
FIG. 10 is a front view of the stapler support assembly of FIG. 9, illustrated in a raised position.
FIG. 11 is a perspective view of a stapler of the machine of FIG. 1.
FIG. 12A is a section view of a portion of the stapler of FIG. 11.
FIG. 12B is a section of a portion of the stapler of FIG. 11
FIG. 13 is another perspective view of the stapler of FIG. 11.
FIG. 14 is a perspective view of the stapler of FIG. 11, including a stapler descent sensor.
FIG. 15 is a perspective view of a portion of the stapler of FIG. 11, including a staple magazine.
FIG. 16 is a perspective view of a portion of the stapler of FIG. 11, including the magazine filled with sticks of staples.
FIG. 16A is a section of a portion of the stapler of FIG. 11.
FIG. 17 is a perspective view of a portion of the stapler of FIG. 11, including a staple pusher and a stapler support rail.
FIG. 18 is a perspective view of a portion of the stapler of FIG. 11, including the staple pusher and the staple support rail.
FIG. 19 is a perspective view of a portion of the stapler of FIG. 11, including the staple pusher and the staple support rail.
FIG. 20 is a perspective view of a portion of the stapler of FIG. 11, including a wire grip.
FIG. 21 is an exploded perspective view of a portion of the stapler of FIG. 11, including the wire grip.
FIG. 22A is a section view of the wire grip of FIG. 20.
FIG. 22B is a section view of the wire grip of FIG. 20.
FIG. 23 is a side view of an exemplary embodiment of a grip housing of the wire grip of FIG. 20.
FIG. 24 is a perspective view of an exemplary embodiment of an outfeed table assembly of the machine of FIG. 1.
FIG. 25 is a perspective view of a portion of the outfeed table assembly of FIG. 24, including the foundation gripper assembly.
FIG. 26 is a flowchart illustrating a portion of a method of assembling a bedding foundation.
FIG. 27 is a flowchart illustrating a portion of the method of assembling a bedding foundation.
FIG. 28 is a flowchart illustrating a portion of the method of assembling a bedding foundation.
FIG. 29 is a flowchart illustrating a portion of the method of assembling a bedding foundation.
FIG. 30 is a flowchart illustrating a portion of the method of assembling a bedding foundation.
FIG. 31 is a flowchart illustrating a portion of the method of assembling a bedding foundation.
Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The disclosure is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. As used herein and in the appended claims, terms such as, for example, “upper,” “lower,” “top,” “bottom,” “front,” “back,” “right,” “left,” and other directional terms are not intended to require any particular orientation but are instead used for purposes of description only.
Terms of approximation, such as “generally,” “approximately,” or “substantially,” include values within ten percent greater or less than the stated value. When used in the context of an angle or direction, such terms include within ten degrees greater or less than the stated angle or direction. For example, “generally vertical” includes directions within ten degrees of vertical in any direction, e.g., clockwise or counterclockwise.
DETAILED DESCRIPTION
FIG. 1 illustrates an apparatus or machine 10 for assembling a bedding foundation 14 (hereinafter “foundation,” an exemplary embodiment of which is illustrated in FIG. 2) having an upper wire grid 18 formed from rows of spring modules 22 and an underlying frame assembly 26, including an outer frame 30 and lateral braces 34 extending across the outer frame 30, to support the grid 18 and to which the grid 18 is coupled by fasteners, such as, for example, staples (for ease of reference and the sake of brevity all types of fasteners that could be used to secure the wire grid 18 to the frame assembly 26 will be referred to as “staples,” which should not be regarded as limiting).
With reference to FIG. 2, in the disclosed exemplary embodiment, the wire grid 18 includes a border wire 38 and the spring modules 22 are formed as a plurality of interior transverse wires 42 that are evenly spaced along a length of the wire grid 18. Each transverse wire 42 extends across a width of the grid 18 and is coupled at its ends to opposite lateral sides of the border wire 38. Each transverse wire 42 is continuous from one side of the wire grid 18 to the other and forms a series of regularly spaced valleys or troughs 46 each positioned between opposed peaks 50 that are generally horizontal and coplanar with the border wire 38. In the disclosed exemplary embodiment, each trough 46 forms an individual spring 54 with two side portions 58 that each extend downwardly from one of the opposed horizontal peaks 50, and a bottom horizontal portion 62 that connects the two side portions 58. The bottom or foot portion 62 of each trough 46 is fastened (e.g., stapled) to the outer frame 30 or one of the lateral braces 34 of the underlying frame assembly 26, as will be further explained. In some embodiments, the shape of each spring 54 above the foot portion 62 may vary. For example, the springs 54 may be shaped as spirals or coils. In the illustrated embodiment, each transverse wire 42 forms a single row of six springs 54 that extends across the width of the wire grid 18. In other embodiments, each transverse wire 42 may form a greater or lesser number of springs 54.
Returning to FIG. 1, the machine 10 comprises first, second, and third portions or sections 36, 40, 44, that support a pneumatic distribution system 48 configured to generate an airflow to various components as will be described below. The pneumatic distribution system 48 includes a supply tank 52 configured to store a volume of compressed gas, a plurality of air lines (not pictured) coupled between the supply tank 52 and various pneumatic components of the machine 10, and other control components (e.g., regulators 56, gauges, valves, etc.) configured to control and monitor the flow of air through the pneumatic distribution system 48. In other embodiments, the machine 10 may instead include an electrical or hydraulic distribution system in place of the pneumatic distribution system 48 to electrically or hydraulicly power various components for operation of the machine 10. In some embodiments, combinations of pneumatic, electric, and/or hydraulic systems may be used.
In some embodiments, a lift assembly (not pictured) may be coupled to the machine 10 and configured to lift a frame assembly 26 and/or grid 18 onto the machine 10 for assembly of the foundation 14. In other embodiments, the lift assembly may be positioned adjacent to or above the machine 10. In yet other embodiments, the lift assembly may be a user-operated lift assembly that lifts a frame and/or wire grid in response to inputs by the user. For instance, the user-operated lift assembly may be a chain or rope hoist crane, gantry crane, or other type of overhead lift assembly. In other embodiments, the lift assembly may be a robotic or automated lift assembly, that is, a lift assembly that operates with little or no input from the operator. In some embodiments, the lift assembly may be a three-axis lift assembly configured to lift and move an object in three orthogonal directions. In other embodiments, the lift assembly may be an articulated lift assembly. Other types of lift assemblies may be used instead.
With continued reference to FIG. 1, the machine 10 also includes a control system 60 (illustrated schematically) including a controller 64 (e.g., illustrated schematically as supported in a control cabinet 68, although it may be located elsewhere) configured to send and receive signals to and from sensors and other diagnostic components to monitor and control operation of the machine 10. The controller 64 may include, for example, one or more micro-processors and non-transitory, machine-readable memory containing software for carrying out the control and operation of the machine 10. The illustrated machine 10 also includes an input/output interface 72 (e.g., a touchscreen display) that can receive input from an operator, communicate the input to the controller 64, display information regarding the machine 10 to the operator (e.g., operating status and apparatus conditions, fault information, etc.), or carry out other functions.
With reference to FIGS. 1 and 3, the illustrated machine 10 includes a protective enclosure 76 that at least partially surrounds the second and third sections 40, 44 of the machine 10. With particular reference to FIG. 3, the protective enclosure 76 includes physical barriers (e.g., fencing 82) to limit entry of an operator, bystander, or foreign object into the protective enclosure 76. The protective enclosure 76 may include other protective features such as an emergency shut-off switch 86 to temporarily disable operation of the machine 10. In other embodiments, the protective enclosure 76 includes other protective structures, such as a light curtain (i.e., a photoelectric safety curtain), or other automatic emergency shut-off features.
The protective enclosure 76 supports an indicator system 90 (e.g., two LED light bars) configured to output more than one lighting color indicative of the operational status of the machine 10, as will be discussed further below. In other embodiments, the indicator system 90 may be a tower light (e.g., a substantially vertical support having multiple light sources configured to emit different color lights), or other visual indicators. Other embodiments may include an audible system that sounds alarms, bells, whistles, etc. as an auditory indicator of the status of the machine 10. The protective enclosure 76 may include one or more gates 94 (e.g., two gates) to allow entry to the protective enclosure 76 to address operational faults, resupply expendable assembly components (e.g., staples), etc.
With reference to FIG. 4, an embodiment of the first section 36 comprising an infeed table assembly is illustrated in greater detail. The infeed table assembly 36 includes an infeed table frame 98 that supports the supply tank 52 and regulator 56. The infeed table frame 98 includes infeed table rails 100 that define an upper surface (illustrated as plane 102 in dashed lines) configured to receive a frame assembly 26 of the foundation 14 for assembly. The infeed table frame 98 has a first extension portion 106 and a second opposed extension portion 110 that define the longitudinal sides 114, 118 of the infeed table assembly 36. A space 122 is defined between the first and second extension portions 106, 110 for entry by an operator to, for example, approach the second section 40. An alignment wall 126 is positioned along the longitudinal side 114, or outer edge, of the first extension portion 106 (e.g., in a direction away from a centerline 130 of the machine 10) and supports a positioning wall 134. The alignment wall 126 has a head surface 138 against which the frame assembly 26 is abutted to align the frame assembly 26 on the infeed table 36 for assembly. The positioning wall 134 defines an abutment surface 142 and is movable toward and away from the centerline 130 of the machine 10 as needed to align the grid 18 in a position above the frame assembly 26.
With reference to FIGS. 4-6, the infeed table assembly 36 includes a sensing system 146 that determines a size of the foundation 14 and sends one or more signals indicative of the foundation's size to the controller 64. The sensing system 146 includes sensors 150 (e.g., seven sensors, shown in FIGS. 5-6), with a first set of the sensors 150 (e.g., four sensors) positioned along and adjacent to the alignment wall 126 and the outer, longitudinal side 114 of the first extension portion 106 of the infeed table assembly 36. A second set of the sensors 150 (e.g., three sensors) is positioned along a transverse edge 154 that extends between and joins the first and second extension portions 106, 110. In the disclosed exemplary embodiment, the sensors are optical sensors (e.g., photo-eye sensors) or other sensors configured to determine a size of the foundation 14. The first set of sensors 150 determines a width of the frame assembly 26, and thereby, the width of the foundation 14, and the second set of sensors 150 determines the length of the frame assembly 26, and thereby, the length of the foundation 14. The sensors 150 thus provide one or more signals to the controller 64 that indicate the length and width of the foundation 14 (e.g., size signals). In other embodiments, a scanner (e.g., a barcode scanner) may be provided on the infeed table assembly 36 for scanning a barcode affixed to the frame assembly 26 and/or wire grid 18 that indicates the size of the foundation 14 and then sends a signal based on the scanned barcode indicating the foundation's size to the controller 64.
With reference to FIGS. 7 and 8, the second section 40 comprising a bridge section includes first and second side plates 158, 162, a first or upper center plate 166, and a second or lower center plate 170. The center plates 166, 170 extend between the first and second side plates 158, 162 above the first and third sections 36, 44. A stapling assembly 174 is coupled to the upper center plate 166 and a stapler support assembly 178 is coupled to the lower center plate 170 for supporting the frame assembly 26 during a stapling operation.
With reference to FIGS. 9 and 10, the stapler support assembly 178 includes a support base 182 that extends between first and second vertical side supports 186, 190. A lower horizontal slide bar 194 is slidably supported on the support base 182 for movement along first directions D1 indicated by a double-headed arrow (e.g., a horizontal direction). An upper support bar 198 is slidably supported on the first and second side supports 186, 190 for movement between a lowered position (FIG. 9) and a raised position (FIG. 10) in second directions D2 indicated by a double-headed arrow that is orthogonal to the first directions D1. Linkages 202 (e.g., seven linkages, although the number of linkages may be greater or less) are pivotally coupled between the slide bar 194 and the support bar 198. As illustrated in FIG. 10, when the slide bar 194 is translated to the left from its position in FIG. 9, support bar 198 is raised by linkages 202 to engage and support the bottom of at least a portion of the frame assembly 26 (e.g., the lateral braces 34). In this raised position, the support bar 198 supports the frame assembly 26, and in particular, the lateral braces 34, during a stapling operation to prevent the stapling assembly 174 from damaging the frame assembly 26 as the stapling assembly 174 presses downward against the wire grid 18 and frame assembly 26 to fire the staples over the wire grid 18 and into the underlying frame assembly 26. It will be appreciated that the support bar provides a solid foundation beneath the lateral braces 34 thereby ensuring the fasteners (e.g., staples 266) are fully seated to the lateral brace 34, securing the wire grid 18. The support bar 198 may include one or more recesses 204 positioned to align with and receive bottom portions of the frame assembly 26.
In more detail, a support actuator 206 fixedly coupled to the second side support 190 is operatively coupled to the slide bar 194 by a threaded rod 210. The support actuator 206 of the present embodiment is a pneumatic cylinder 214 in which a piston (not shown) is disposed and operatively coupled to the threaded rod 210. Increasing pressure on one side of the piston causes the piston to slide within the cylinder and translate the slide bar 194 to the left from the position shown in FIG. 9 to the position shown in FIG. 10 along the first direction D1. Linear motion of the slide bar 194 along the first direction is translated to linear motion of the support bar 198 along the second direction D2 through the linkages 202 that interconnect the slide bar 194 with the support bar 198. As the slide bar 194 moves to the left in FIG. 10, the slide bar 194 pivots linkages 202 in a clockwise direction to raise the support bar 198 along the direction D2 to the position shown in FIG. 10. When the slide bar 194 moves back to the right in FIG. 9 after raising the support bar 198, the slide bar 194 pivots the linkages 202 in a counterclockwise direction to lower the support bar 198 along the direction D2. In other embodiments, another linear actuator such as a solenoid may be used as the support actuator instead of pneumatic cylinder 214. In still other embodiments, the support actuator may be a motor coupled to the slide bar by a gear assembly (e.g., a worm gear coupled to the motor output shaft and a rack coupled to the slide bar) or other structure to transfer rotational motion of the motor to linear motion of the slide bar.
Returning with reference to FIGS. 7 and 8, the stapling assembly 174 includes a bank of staplers 218 (e.g., seven staplers, although the number of staplers may be greater or less than seven, depending on the construction or size of the frame assembly 26 and the wire grid 18) that are slidably supported on one or more horizontal or longitudinal guide rails 222 (e.g., two guide rails) for longitudinal positioning each of the staplers 218 in unison across the width of the stapler assembly 174. Each stapler 218 includes a stapler carriage 226 that is slidable along the guide rails 222. A linkage assembly 230 (e.g., a scissor linkage as illustrated in FIG. 8) is supported on a side of the upper center plate 166 opposite the one or more guide rails 222 and is coupled to each of the stapler carriages 226. Thus, all the staplers will translate together the same distance along guide rails 222 when linkage assembly 230 is actuated (i.e., expanded or contracted) to accommodate foundations of different sizes or constructions, as explained below.
A stapler actuator 234 (e.g., an AC servo motor) is operatively coupled to the linkage assembly 230 by a stapler rod 238 (e.g., a threaded rod) and an internally threaded bushing 242 that is attached to the stapler carriage 226 closest to the actuator 234. In other embodiments, the stapler actuator may be a pneumatic actuator. Stapler rod 238 extends through threaded bushing 242 such that rotation of the stapler rod 238 by stapler actuator 234 causes the threaded bushing 242 to travel along the threaded stapler rod 238 either away from or toward the stapler actuator 234, depending on the direction of rotation of the stapler rod 238. Accordingly, the stapler carriage 226 to which the bushing 242 is attached will translate either toward or away from the stapler actuator 234, depending on whether the stapler rod 238 is rotated in a clockwise or counterclockwise direction. Because all the stapler carriages 226 are operatively coupled to the same linkage assembly 230, translation of the stapler carriage 226 that supports the threaded bushing 242 causes the entire linkage assembly 230 to expand or contract and translate all the attached stapler carriages 226 in unison. Thus, depending on the direction of rotation of stapler rod 238 (clockwise or counterclockwise), the linkage assembly 230 will either expand or contract.
Expansion of the linkage assembly 230 will cause all the stapler carriages 226 to move farther apart from one another the same distance along guide rails 222. Contraction of the linkage assembly 230 will cause all the stapler carriages 226 to move closer together the same distance along guide rails 222. Thus, the rotational motion imparted by stapler actuator 234 to stapler rod 238 is translated to linear motion by threaded bushing 242 and linkage assembly 230 to move the stapler carriages 226 along guide rails 222 farther apart or closer together to adjust for different constructed or sized spring modules 22 and frame assemblies 26.
FIGS. 11-22B illustrate an exemplary embodiment of a stapler 218. With particular reference to FIGS. 11-14, the stapler 218 includes a slide carriage 246 that is slidable along one or more stapler guide rails 250, which extend between and are coupled to a base plate 252 and a top plate 253 provided on the stapler carriage 226. A stapler cylinder 254 is coupled to the slide carriage 246 for movement up and down with the slide carriage 246 along the stapler guide rails 250. A stapler head 258 extends downward from the bottom end of the stapler cylinder 254 for movement with the stapler cylinder 254 and firing the staples used to attach the wire grid 18 to the underlying frame assembly 26. A magazine 262 stores staples 266 (shown in FIG. 16) for firing into the frame assembly 26 to secure the individual spring modules 22 of wire grid 18 to the frame assembly 26. The magazine 262 is coupled to the stapler head 258 and stapler cylinder 254 (e.g., by braces 270) for vertical movement with the stapler head 258 and stapler cylinder 254. A wire gripper 274 is coupled to a distal end of the stapler head 258 opposite the stapler cylinder 254.
As shown in FIGS. 12A-12B, a stapler blade 278 with an attached stapler piston 280 are slidably supported within the stapler cylinder 254 and stapler head 258. As described in more detail below, for each stapling operation, the bottom of the stapler blade 278 is positioned adjacent to the staple magazine 262 to receive one or more staples (e.g., two staples) for firing. Once a staple 266 is loaded from the magazine 262 into the staple head 258 beneath the stapler blade 278 for firing, the stapler 218 is ready for stapling. Returning to FIGS. 11-14, when the wire grid 18 is properly positioned beneath the stapler assembly 174 for stapling (see FIG. 22B), the staplers 218 can be lowered by the control system 60 toward the wire grid 18. In some embodiments, the machine 10 may include a vision system, such as vision system 200 described and illustrated in U.S. Pat. No. 11,304,535 to L&P Property Management Company, the entire content of which is incorporated herein by reference. The vision system may communicate with the control system 60 to provide feedback used to determine the location of the wire grid 18, which may in turn be used by the control system 60 to adjust a spacing and/or tilt angle of the staplers 218.
The stapler piston 280 attached to each stapler 218 can be actuated when the stapler 218 has been lowered by the control system 60 to a threshold firing position above the wire grid. The actuated stapler piston 280 will generate a downward pneumatic pressure that forcefully drives the attached stapler blade 278 downward within the stapler cylinder 254 and stapler head 258. The fast downward moving stapler blade 278 fires (i.e., pushes) the staple 266 through and out of the stapler head 258 over the bottom portion 62 of the targeted spring 54 and into the frame assembly 26.
In more detail, the slide carriage 246 is slidably supported on one or more stapler guide rails 250 for movement between a raised position (FIG. 11) and a lowered firing position (FIG. 13) as illustrated by double-headed arrow D3 by, for example, application of pneumatic pressure. The stapler 218 can begin and continue its descent along guide rails 250 under a first, relatively low pressure. It will be appreciated that descent under a first low pressure reduces the likelihood of damage to the grid 18 or the frame assembly 26 if a stapler 218 is not properly aligned with the wire grid 18 and inadvertently strikes the grid 18 during the stapler's descent. Once the stapler 218 has descended past a point where the potential for damaging the grid 18 by an inadvertent strike has been minimized (e.g., when the stapler 218 is in the lowered position), a second higher pressure is applied to the stapler to maintain the stapler in the lowered position and impart a greater force through the stapler head 258, ensuring the staple 266 is fully seated when fired into the frame.
Stapler descent sensor 286 (e.g., a proximity sensor such as a reed switch, FIG. 14) sends signals to the controller 64 indicating the stapler's position relative to the top plate 253 as the stapler 218 descends toward the bedding foundation 14 to fire a staple 266. The controller 64 uses the position signals received from the sensor 286 to compare the position of the descending stapler 218 to a programmed threshold position. When the stapler 218 reaches the threshold position, the controller 64 actuates the stapler piston 280 with attached stapler blade 278 to fire the staple 266 from the stapler head 258 for fastening the wire grid 18 to the underlying frame assembly 26. For a stapler 218 that is powered by an electric system instead of pneumatic system, an encoder may be used in place of a proximity sensor.
With reference to FIGS. 15-19, the magazine 262 defines a compartment 294 in which a ram 298 is slidably supported. The ram 298 is initially positioned at one end of the magazine compartment 294 adjacent end plate 314 and distal from the stapler head 258 for loading the magazine with staple clips 318. The ram 298 is biased by one or more biasing elements 302 (e.g., strip springs) supported along the magazine's side plates 306 in a direction D4 along the length of the magazine 262 toward the end of magazine proximate the stapler head 258. The ram 298 includes a latch 310 that is selectively engageable with an end plate 314 of the magazine 262 to hold the ram 298 in position adjacent the end plate 314 against the biasing force of the biasing elements 302 when the magazine compartment 294 is not full. Release of the latch 310 by an operator when stapling operations are to begin allows the biasing element(s) 302 to bias the ram 298 in the direction D4 toward the stapler head 258. The ram 298 thus biases (i.e., pushes) the staple clips 318 (which each may comprise a group of staples temporarily coupled together in a substantially linear arrangement) that are stored in the magazine compartment 294 toward the stapler head 258 along direction D4.
In the disclosed exemplary embodiment, each clip 318 comprises a plurality of inverted-U-shaped staples 266 that are stored in the magazine's compartment 294 such that the U-shaped cavity 346 between the legs of the staples 266 opens toward the magazine compartment's bottom surface 320. As illustrated in FIGS. 15-19, and in particular FIG. 16A, an inverted U-shaped staple pusher 322 and a relatively flat staple support rail 326 are slidably supported at an end 330 of the magazine 262 opposite the end plate 314 and proximate the stapler head 258. When the pusher 322 and staple support rail 326 are positioned adjacent the opening 328 in the magazine 262 through which the staples 266 are fed into the stapler head 258, referred to below as an “engaged” position, the staple support rail 326 is positioned underneath (i.e., inside) the U-shaped cavity 346 of the staple clip 318. It will be appreciated that this arrangement maintains the staples 266 of the clip 318 in alignment in a single row as the staple pusher 322 pushes the staples 266 into the stapler head 258.
The staple pusher 322 is coupled to a staple pusher carriage 334 and the staple support rail 326 is coupled to a staple support carriage 338. The staple pusher carriage 334 and the staple support carriage 338 are slidably supported in a direction transverse to the length of magazine 262 along a pair of parallel spaced apart carriage rails 342 between a first, disengaged position spaced from the stapler head 258 as illustrated in FIG. 17 and a second engaged position adjacent the opening 328 in the magazine 262 through which the staples 266 are loaded into the stapler head 258, as illustrated in FIGS. 16 and 19. In FIG. 18, the staple support rail 326 is positioned in the engaged position adjacent the opening 328 in the magazine 262 through which the staples are loaded into stapler head 258 and the staple pusher 322 is positioned in the disengaged position distal from the opening 328. As shown from the perspective of FIG. 16, the staple support carriage 338 and its carriage rail 342 are positioned below the staple pusher carriage 334 and its carriage rails 342.
In more detail, when the magazine is first loaded with staples 266, both the staple support rail 326 and the staple pusher 322 are in their disengaged positions illustrated in FIG. 17. In other words, the staple support rail 326 and the staple pusher 322 are positioned out of the path the clips 318 travel in the magazine compartment 294 to their loading position adjacent opening 328. As mentioned, the staple support rail 326 is configured to slide within the U-shaped cavity 346 defined between the legs of the fasteners 266 (i.e., the staples in the exemplary embodiment).
Once the magazine is loaded with staples 266, the staple support carriage 338 will move the staple support rail 326 along direction D5 (FIG. 16) under pneumatic pressure from its disengaged position illustrated in FIG. 17 to its engaged position illustrated in FIGS. 18 and 19, which will place the staple guide rail 326 within the U-shaped cavity 346 defined between the legs of the staples 266 (not shown in FIG. 18). The staple guide rail 326 is now positioned to keep the staples 266 aligned in a row for loading through opening 328 into the stapler head 258.
With the staple guide rail 326 moved to its engaged position, the staple pusher carriage 334 will move the staple pusher 322 under pneumatic pressure along direction D5 (FIG. 16) from its disengaged position illustrated in FIGS. 17 and 18 toward the engaged position to an intermediate position in which it is engaged with the end of the clip 318 of staples 266 in FIGS. 16 and 19. In this intermediate position, the inverted U-shaped staple pusher 322 is positioned over the staple clip 318 and an end of the staple pusher 322 facing the opening 328 engages the last staple 266 in the clip 318 to sequentially push the clip 318 of staples 266 through opening 328 for loading staple head 258 as the staples are needed for stapling. After the staples 266 are advanced through the opening 328 and into the staple head 258, the pneumatic pressure is relieved and the staple pusher 322 and staple pusher carriage 334 maintain their position in the magazine without applying a force to the staples 266 to advance staples 266 through the opening 328. Following completion of a stapling operation (i.e., firing one or more staples 266 to fasten a wire of the grid 18 to the frame assembly 26, and the stapler blade 278 returning to its raised position in preparation for a subsequent firing), pneumatic pressure is again applied to the staple pusher carriage 334 and staple pusher 322 to advance the next staple 266 through the opening 328.
Each time a clip 318 of staples 266 has been spent and a new staple clip 318 needs to be advanced to opening 328 for loading into the stapler head 258, staple pusher carriage 334 will move the staple pusher 322 in a direction opposite D5 (FIG. 16) from its engaged position illustrated in FIGS. 16 and 19 to its disengaged position illustrated in FIGS. 17 and 18. Either separately or concurrently, the staple support carriage 338 will move the staple guide rail 326 in a direction opposite to D5 (FIG. 16) from its engaged position illustrated in FIGS. 18 and 19 to its disengaged position illustrated in FIG. 17. The path is now clear for ram 298 to push another staple clip 318 into position at the end of the magazine compartment 294 adjacent the opening 328 for loading into stapler head 258.
A staple advancement system 350 (FIG. 16), including a staple positional sensor 354 (e.g., a magnetic position sensor), is coupled to the magazine 262 to detect the distance the staple pusher carriage 334 moves. The staple positional sensor 354 may be, for instance, Actuator Position Sensor D-MP #Series sensor, produced by SMC Corporation, of Tokyo, Japan. Other sensors configured to measure changes in in the movement of staple pusher carriage 334 may be used instead. The staple positional sensor 354 can detect the movement of the staple pusher carriage 334 within a distance of approximately 2 mm, which is accurate enough to detect movement of the staple support carriage 334 when it moves the stapler pusher 322 to load a staple 266 into the stapler head 258 after a staple 266 has been fired (e.g., two staples having a width of about 0.125 inches, or approximately 3 mm). The distance the staple pusher carriage 334 moves as detected by staple positional sensor 354 indicates whether a staple was fired from the stapler head 258 into the frame assembly 26. That is, each time a fastener 266 is fired, the staple pusher carriage 334 will move the staple pusher 322 to load another staple 266 into the stapler head 258. Movement of the staple pusher carriage 334 to load another staple 266 into the stapler head 258 is detected by the staple positional sensor 354 which signals that a staple 266 has been fired by the stapler head 258. Lack of movement of the staple pusher carriage 334, and thus either a lack of a signal, or a lack of a change in the signal indicates that no staple 266 was fired (e.g., the staple is jammed). The staple advancement system 350 thus provides a signal to the controller 64 indicative of whether a staple 266 was fired.
FIGS. 20-22B illustrate an embodiment of the wire gripper 274. The wire gripper 274 includes a grip housing 358 coupled to the stapler head 258 by a gripper clamp 362 and fasteners 366. First and second grip plates 370, 374 are arranged and pivotally supported within grip housing 358 in a facing relationship by cam pins 378 and a pivot pin 382. A spring 386 positioned within the grip housing 358 biases the grip plates 370, 374 downwardly toward a bottom end 414 of grip housing 358 such that the distal ends of grip plates 370, 374 are spaced apart and away from each other as shown in FIG. 22A.
A separation plate 390 is coupled to the gripper clamp 362 (e.g., by fasteners) and is positioned to separate adjacent wires of the grid 18 from the wire to be fastened to the frame assembly 26. The separation plate 390 has a width W1 (FIG. 21) of about 2 inches, although other dimensions may be used instead. The distance L1 (FIG. 20) from the separation plate 390 to the centerline 394 of the stapler head 258 is approximately 0.875 inches, although other distances may be used instead depending on the distance between adjacent wires of the grid 18. An isolation plate 398 is coupled between the stapler head 258, on the one hand, and the grip housing 358 and the grip plates 370, 374, on the other hand. The isolation plate 398 is made of a non-conductive material to electrically isolate the grip housing 358 and the grip plates 370, 374 from the stapler head 258. A wire detection sensor 402 (e.g., a ground detection circuit, illustrated schematically in FIG. 20) is electrically coupled to the grip housing 358.
With continued reference to FIGS. 20-22B, the grip housing 358 defines a pair of cam slots 406 that extend at least partially between the grip housing's first top end 410 and second bottom end 414. The cam slots 406 each include a first upper cam portion 418 that extends downward in a substantially vertical direction and a second lower cam portion 422 that extends inwardly from the first portion at an angle A1 relative to the first cam portion 418, that is, at an angle relative to vertical. In the disclosed embodiment, the second cam portion 422 extends at an approximately thirteen-degree angle inwardly from the vertical first cam portions 418. In other embodiments, the second cam portion 422 may extend at another angle relative to the first cam portion 418. In another embodiment, illustrated in FIG. 23, the cam slots 406 may have another profile.
Returning to FIGS. 20-22B, an alignment slot 426 is positioned at least partially between the cam slots 406 closer to the second, bottom end 414 of the grip housing 358 and extends in a substantially vertical direction. A bore 430 extends from the first, top end 410 of the grip housing 358 and through the grip housing to the alignment slot 426 for receiving and supporting the spring 386. A fastener 438 (e.g., a set screw) maintains the spring 386 within the bore 430.
Each of the grip plates 370, 374 includes a pin portion 442 having a cam hole 446 located at a first top end 450. Cam pins 378 are received in cam holes 446. A grip portion 454 of each grip plate 370, 374 extends from the pin portion 442 at an angle relative to the pin portion 442. A pivot hole 458 is provided in each of the grip plates 370, 374 at the transition between the pin portion 442 and the grip portion 454 of the grip plates. A pivot pin 382 is disposed in the pivot hole 458. A tab 462 extends downwardly from the bottom end 466 of the grip portion 454 of each grip plate 370, 374 opposite the pin portion 442. The tabs 462 of the grip plates 370, 374 together define between them a receiving gap 470 configured to receive and grasp the bottom portion 62 of each wire module 22 of wire grid 18 to grip and position the wire module 22 for stapling the grid 18 to the frame assembly 26.
The cam pins 378 coupled to the pin portion 442 of each grip plate 370, 374 are slidably received in the cam slots 406. The pivot pin 382 is slidably received in and extends through the alignment slot 426 and engages the bottom end of the spring 386. As illustrated in FIG. 22A, when the stapler 218 is at its raised or highest position (FIG. 11), the cam pins 378 are positioned at the second bottom end 414 of the cam slots 406 and the grip plates 370, 374 are fully extended from the grip housing 358 due to the downward biasing force applied to the pivot pin 382 by the spring 386. In this position, the tabs 462 are spaced apart the greatest possible distance permitted by the configuration of the grip housing 358.
As the stapler 218 is moved downward in a first direction (e.g., a vertical direction D3 in FIG. 11) the plates 370, 374 engage the frame assembly 26 and/or grid 18. Engagement of the plates 370, 374 with the frame assembly 26 counteracts the biasing force of the spring 386 applied to the pivot pin 382 and stops the downward movement or descent of the grip plates 370, 374 relative to the wire grid 18 and frame assembly 26. In other words, the bottom ends of the grip plates 370, 374 are resting on the top surface of the frame assembly 26 with the bottom portion 62 of the wire module 22 positioned in the gap 470 between the tabs 462 formed at the bottom end of each grip plate 370, 374. As a result, the continued descent of the stapler 218 moves the grip housing 358 downwardly over the now vertically stationary grip plates 370, 374 (see relative positions of the grip plates 370, 374 in FIGS. 22A compared to their positions in FIG. 22B). As the grip housing 358 moves downward in its stapling descent over the grip plates 370, 374, the cam pins 378 move upward in the cam slots 406 to pivot the grip plates 370, 374 about pivot pin 382 (illustrated as rotation R1 in FIG. 22A) such that the bottom ends of the grip plates 370, 374 with tabs 462 move inwardly toward each other to narrow the receiving gap 470. As the stapler 218 continues its descent, the grip plate tabs 462 come together to grasp between them the bottom portion 62 of the wire module 22 and hold the bottom portion 62 in alignment with the stapler 218 for firing a staple 266 over the bottom portion 62 and into the frame assembly 26 to fasten the grid 18 to the frame assembly 26, as illustrated in FIG. 22B.
The wire detection sensor 402 measures when a current passes through the grip housing 358 and/or grip plates 370, 374 to the grid 18 as the plates 370, 374 grasp the grid 18 to position and hold the grid 18 for stapling. Conduction of a current through the grid 18 results in a ground condition of the current. Upon detection of a ground condition, the wire detection sensor 402 transmits a signal indicating that the wire gripper 274 has secured the grid 18 in place for stapling and that a stapling operation can commence. The wire detection sensor 402 is part of an apparatus monitoring system at least partially supported in the second bridge section 40.
With reference to FIGS. 24-25 an embodiment of the third section 44, the outfeed table assembly, is illustrated. The outfeed table assembly 44 receives the foundation 14 from the infeed table assembly 36 and bridge section 40 and advances the foundation 14 for successive fastening of the grid 18 to the frame assembly 26. The outfeed table assembly 44 includes an outfeed table frame 478 with supporting rails 482 that extend along the length of the outfeed table frame 478 and define a support plane 484 (shown in dashed lines) along which the foundation 14 moves. The outfeed table frame 478 supports a carriage 486 positioned to travel below the support plane 484 and configured to translate along outfeed table guide rods 490 that are supported by the outfeed table frame 478. Carriage 486 is configured to removably grasp a front end of the foundation 14 to incrementally pull the foundation 14 along the rails 482 for successive stapling of each of the wire modules 22 to the frame assembly 26. The carriage 486 may be translated along the outfeed table guide rods 490 by an electric system (e.g., an AC servo motor). Alternatively, the carriage 486 may be moved along the outfeed table guide rods 490 by a pneumatic system.
The carriage 486 includes one or more foundation gripper assemblies 494 (e.g., two foundation grippers 494). With reference to FIG. 25, each foundation gripper assembly 494 includes a support portion 498 that extends vertically from a base portion 502, to which a frame grip 506 (e.g., a pneumatic gripper) is also coupled. The frame grip 506 has a jaw-like configuration to grasp a front portion of each frame assembly 26 when placed on the infeed table assembly 36 under bridge section 40. A contact plate 510 is coupled to a vertical front portion 514 of the support portion 498 and is positioned above the frame grip 506. The frame grip 506 and contact plate 510 are each configured to face a foundation 14 placed on the infeed table assembly 36 under the bridge section 40. A grid detection sensor 518 (illustrated schematically in FIG. 25) is electrically coupled to the contact plate 510. The grid detection sensor 518 may be a ground detection sensor that detects a ground condition created by an electrical current conducted through the contact plate 510 when engaged by a wire grid 18 placed on the infeed table assembly 36. The grid detector then sends a signal to the controller 64 to indicate that a ground condition between the contact plate 510 and the wire grid 18 exists (i.e., a wire grid 18 has been placed on the infeed table assembly 36 and engaged the contact plate 510). In other embodiments, other sensors may be coupled to the one or more foundation gripper assemblies 494 to detect the presence of the grid 18.
A frame detection sensor 522 is coupled to the frame grip 506. In the illustrated embodiment, the frame detection sensor 522 is a positional detent sensor that is depressed by the front end of the frame assembly 26 when the frame assembly 26 is received within the frame grip 506. In other embodiments, other sensors (e.g., optical sensors) may be used. The grid detection sensor 518 and the frame detection sensor 522 are components of a carriage advancement system 526, which is also part of the apparatus monitoring system. Pneumatic pressure supplied to the frame grip 506 depresses the frame grip 506 to hold the frame assembly 26 for incrementally transporting the foundation 14 beneath the bridge section for stapling and along the infeed table assembly 36 and the outfeed table assembly 44 as stapling operations proceed and are completed.
Returning to FIG. 24, the foundation is incrementally translated by the carriage 486, together with the attached foundation gripper assemblies 494, in a horizontal direction D7 along the outfeed table guide rods 490 from a “start” position (FIG. 24), in which the gripper assemblies 494 are extended above the foundation support plane 484, adjacent the end 530 proximate the infeed table assembly 36 and the bridge section 40, to an “eject” position. Incremental translation of the foundation 14 by the carriage 486 and foundation gripper assemblies 494 moves the foundation relative to the infeed table 36 and bridge section 40 for successive stapling of the grid 18 to the frame assembly 26. The one or more foundation gripper assemblies 494 can be extended above and lowered below the foundation support plane 484 along a vertical direction D8 (shown in FIG. 24). In the lowered position, the foundation 14 may be lifted off the outfeed table's rails 482 following completion of the assembly operation without interference with the one or more foundation gripper assemblies 494. The gripper assemblies 494 may then be raised from the lowered position upon return to a position adjacent the bridge section 40 for receiving another foundation 14. Movement of the carriage 486 and gripper assemblies 494 is carried out by pneumatic pressure. In other embodiments, those components may be operated completed by an electrical system or other systems.
FIGS. 26-31 illustrate an exemplary method 1000 of assembling a foundation, which may be implemented, for example, using the machine 10.
With reference to FIG. 26, in a first step 1001, the operator powers on the machine 10 (e.g., by operation of a master power switch or another operation). Following apparatus power-on at step 1001, at step 1002, the indicator system 90 cascades (e.g., the lights of the indicator system 90 are sequentially changed between various colors, increased or decreased in brightness, etc.) as an indication that the machine 10 has been turned on. In some embodiments, other indications of the power status of the machine 10 may be utilized (e.g., a buzzer, bell, etc.). Once the indicator system 90 cascades at step 1002, at the next step 1003, the operator loads staples 266 into the magazines 262. In some embodiments, step 1003 can be completed regardless of the on/off state of the machine 10 and either before or after cascading of the indicator system 90 at step 1002. Following step 1003, at step 1004, the operator selects the product type (e.g., the foundation 14 size). In other embodiments, the controller 64 may determine the product type based on the signals received from the sensing system 146, from a barcode scanner, etc. Following selection of the foundation 14 size, in step 1005, the positioning wall 134 moves to the position associated with the selected foundation 14. In the following step 1006, the one or more foundation gripper assemblies 494 are extended upwardly to a raised position and the carriage 486 is returned from the distal end of the outfeed table assembly 44 to a position adjacent the bridge section 40. Following return of the carriage 486 with the attached one or more foundation gripper assemblies 494, in step 1007, the controller 64 determines whether a robotic lift assembly is coupled with the machine 10 and proceeds to a first subroutine 1008a if a robotic lift assembly is not paired with machine 10 and proceeds to a second subroutine 1008b if a robotic lift assembly is paired with the machine 10.
With reference to FIG. 27, the first subroutine 1008a is shown. Following the determination at step 1007 that a robotic loading attachment is not paired with the machine 10, and proceeding to subroutine 1008a, at the next step 1009, the indicator system 90 turns a blue color indicating that the machine 10 is ready for a bedding foundation 14 including a wire grid 18 and an underlying frame assembly 26 to be loaded on to the infeed table assembly 36. At the next step 1010a, the operator first loads a frame assembly 26 on to the infeed table assembly 36. Following loading of the frame assembly 26, at step 1011, the controller 64 determines whether the frame assembly 26 has triggered the frame detection sensor 522. If the frame assembly 26 did not trigger the frame detection sensor 522, the controller 64 returns to step 1010. If the frame assembly 26 does trigger the frame detection sensor 522, at step 1012, the one or more frame grips 506 close on the frame assembly 26. Following step 1012, at step 1013, the sensors 150 of the sensing system 146 detect the size of the frame assembly 26 and the controller 64 adjusts the machine 10 (e.g., positions the staplers 218 by operation of the stapler actuator 234 and linkage assembly 230) for the proper length and width. Following step 1013, at step 1014, the indicator system 90 flashes a blue light, indicating that the frame grips 506 are closed and the machine 10 is ready for a grid 18 to be loaded onto the frame assembly 26. Following step 1014, at step 1015a, the operator loads a wire grid 18 onto the frame assembly 26. Following step 1015a, at step 1016, the controller 64 determines whether the grid 18 has triggered the grid detection sensor 518. If the grid 18 has not triggered grid detection sensor 518 at step 1016, the controller 64 returns to step 1015a for the operator to load a grid 18. If at step 1016 the grid detection sensor 518 has been triggered by the grid 18, subroutine 1008a is completed and the controller 64 proceeds to step 1017 in which the indicator system 90 emits a green light indicating the machine 10 is running.
With reference to FIG. 28, the second subroutine 1008b is shown. Subroutine 1008b is substantially similar to the subroutine 1008a, and only differences in the subroutine 1008b from subroutine 1008a will be described. The steps that are not discussed are substantially the same. In subroutine 1008b, in step 1010b, the robotic lifting assembly loads a frame assembly 26 onto the infeed table assembly 36. In step 1010b, the robotic lifting assembly loads the wire grid 18 onto the frame assembly 26.
With reference to FIG. 29, following completion of step 1017 in which the indicator system 90 turns green, in step 1018, the controller 64 determines whether the position of the foundation 14 requires the stapler support assembly 178 to be raised to support the frame assembly 26. If the position of the foundation 14 requires support, in step 1019, the controller raises the stapler support assembly 178 to support the foundation 14. If staple support is not needed, the method proceeds to subroutine 1020.
With reference to FIG. 30, following either steps 1018 or 1019, the machine 10 proceeds to subroutine 1020, which is completed for each stapler 218 in the stapling assembly 174. In step 1021, the stapler 218 first descends with a relatively low pneumatic pressure applied. Following step 1021, in step 1022, the controller 64 determines whether the stapler descent sensor 286 has been triggered (i.e., downward movement of the slide carriage 246 and the stapler head 258 meeting or exceeding a staple firing threshold position). If the controller determines in step 1022 that the stapler descent sensor 286 has been triggered, in step 1023, the wire gripper 274 grasps a bottom wire portion of the targeted wire module 22 and moves it into a position to be stapled to the frame assembly 26. If in step 1022, the stapler descent sensor 286 is not triggered, in step 1024, the controller 64 determines whether the stapler descent sensor 286 has failed to be triggered more than one time. If the stapler descent sensor 286 has been triggered only one time, in step 1025, the stapler 218 is raised using high pressure from the pneumatic distribution system 48 and returns to step 1021. If in step 1024, the stapler descent sensor 286 has been triggered more than one time (e.g., two attempts to lower the stapler 218 have not triggered the stapler descent sensor 286), in step 1026, the indicator system 90 flashes a red and blue, indicating a stapler 218 failed to descend. Following step 1026, in step 1027, the operator fixes the fault (e.g., removes the source blocking a stapler 218 from descending). The controller 64 proceeds to step 1028, in which the indicator system 90 turns green indicating the machine 10 is operating, and then returns to step 1021.
Returning to step 1023, once the wire gripper 274 grasps the bottom wire portion of the targeted wire module 22 and moves the bottom wire portion into position, in step 1029, the controller 64 determines whether the wire detection sensor 402 detects the grid 18. If the wire detection sensor 402 detects, the sensor, in step 1030, the pneumatic distribution system 48 applies a relatively high pressure to the stapler 218. If in step 1029, the wire detection sensor 402 has not detected the grid 18, in step 1031, the controller 64 determines whether the lack of detection of the grid 18 has occurred more than once. If the controller 64 has failed to detect the grid 18 only once, the controller 64 returns to step 1025 and proceeds from step 1025 as described above. If in step 1031, the controller 64 detects more than one failure (e.g., two failures to detect the grid 18), in step 1032, the indicator system 90 flashes red and yellow, indicating a wire of the grid 18 was not detected. Following step 1032, the controller 64 returns to step 1027 allowing the operator to fix the fault (e.g., properly position the wire) and proceed from step 1027 as described above.
Following step 1030, in step 1033, the stapler 218 is activated to fire a fastener 266 to fasten the grid 18 to the frame assembly 26 (e.g., the stapler blade 278 engages a fastener 266 from the magazine 262 to fire the fastener 266. Once step 1033 has been completed, in step 1034, the stapler 218 is returned to its raised position. In the next step 1035, the controller 64 determines whether staples 266 were used (e.g., whether the staple positional sensor 354 has sensed that the staple pusher carriage 334 has advanced). If the controller 64 determines that staples 266 were used, the controller 64 proceeds to step 1036. If the determination is made that staples were not used, in step 1037, the controller 64 determines whether the lack of use of staples 266 has occurred more than one time. If staples 266 were not used more than one time, in step 1038, the indicator system 90 flashes red and red and returns to step 1027, allowing the operator to address the source of the fault (e.g., load more staples, fix a jam, etc.) and proceeds from step 1027 as described above. If at step 1037, fasteners 266 failed to advance after only one use, at step 1039, the stapler 218 is activated twice to clear the fasteners 266 and a potential jam that has occurred. Following step 1039, at step 1041 the controller 64 determines whether staples 266 were used. If staples 266 are used, the controller 64 returns to step 1028 and proceeds from step 1028 as describe above. If no fasteners 266 were used at step 1040, the controller 64 returns to step 1038 and proceeds from step 1038 as described above.
Returning to step 1036, the controller 64 determines where the stapler 218 has used all of the staples 266 in a clip 318 (e.g., the stapler 218 is empty, the staple pusher carriage 334 has reached an end position, and staples 266 need to be reloaded form the magazine 262). If the stapler 218 is empty at step 1036, the controller 64 reloads a new clip 318 from the magazine 262 (, i.e., the staple pusher 322 and staple support rail 326 are moved to their first disengaged position under pneumatic pressure allowing a new clip 318 to be advanced adjacent to the proximate end of the magazine 262). If the stapler 218 is not empty at step 1036, at step 1042, the controller 64 determines whether all staplers 218 in the stapling assembly 174 have successfully completed a stapling operation (e.g., to reach step 1042). If not, the controller 64 continues to check if all of the staplers 218 have completed a stapling operation.
With reference to FIG. 31, once the controller 64 has determined at step 1042 that all of the staplers 218 of the stapling assembly 174 have successfully fired a staple 266 into the frame assembly 26, the controller 64 proceeds to step 1043. At step 1043, the controller 64 determines whether the stapler support assembly 178 is in the raised position. If the controller 64 determines that the stapler support assembly 178 is raised, at the following step, step 1044, the stapler support assembly 178 is moved to the lowered position (e.g., the support actuator 206 is activated to slide the slide bar 194 thereby lowering the support bar 198). The controller then proceeds to step 1045. If at step 1043, the stapler support assembly 178 is not in the raised position (e.g., was not raised in step 1019), the controller 64 moves to step 1045, bypassing step 1044.
Following steps 1043 or 1044, at step 1045, the controller 64 determines whether the stapling assembly 174 has completed assembly of a foundation 14 (i.e., that the module grid wire in the last row of the grid 18 has been stapled to the frame assembly 26, which may be determined by a counter function of the controller 64, a sensor configured to measure displacement of the carriage 486, an optical sensor configured to determine the presence or absence of a foundation 14, etc.). If at step 1045, the module grid wire in the last row of the grid 18 has not been stapled, at the following step 1046, the carriage 486 moves the foundation 14 to the next position to be stapled. The controller 64 then returns from step 1046 to step 1017 and proceeds from step 1017 as described above. If at step 1045, the controller 64 determines the module grid wire in the last row of the wire grid 18 has been assembled to the frame assembly 26, at step 1047, the carriage 486 moves to the distal end of the outfeed table assembly 44 (e.g., the eject position) by pneumatic pressure supplied by the pneumatic distribution system 48.
Once at the eject position, at step 1048, the frame grip 506 opens and then at step 1049, the one or more foundation gripper assemblies 494 move to a lowered position, an operator removes the completed bedding foundation 14 from the outfeed table assembly 44, and the carriage 486 passes under the foundation 14 and returns to a position adjacent the bridge section 40. At the following step, step 1050, the controller 64 determines whether the magazine 262 contains a sufficient number of fasteners 266 to complete fastening of another bedding foundation 14 (e.g., a queen-size foundation 14). If at step 1050, the magazine 262 contains enough staples 266, the controller 64 returns to step 1006 and proceeds from step 1006 as described above. If the controller 64 determines that an insufficient number of staples 266 are contained in the magazine 262, at step 1051, the indicator system 90 flash red and white. At the following step 1052, the operate reloads fasteners 266 in the magazine(s) 262 and enters an input (e.g., presses a “continue” button on the input/output interface 72. At the following step 1053, the indicator system 90 is illuminated in a green color (indicating normal operation) and the controller 64 returns to step 1006.
It will be appreciated that any of the operations of the machine 10 described above as being carried out by pneumatic pressure provided by the pneumatic distribution system 48 can instead be completed by electrical structures (e.g., motors, solenoids, etc.) and/or hydraulic structures (e.g., motors, cylinders, etc.).
Although the disclosure has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the disclosure as described.
Various features and aspects of the disclosure are set forth in the following claims.
Patent Application
20250230653
