Abstract: A system for attaching handles to a workpiece, such as for attaching handles to a border material for a mattress. The system includes a pair of sewing heads movably mounted along a sewing area. The sewing heads can be moved from a first position for sewing the handles to the border in a first orientation, such as a horizontal orientation extending along the length of the border, to a second position for sewing the handles to the border in a different orientation, such as a vertical orientation extending across the width or height of the border.

Abstract: A system for attaching handles to a workpiece, such as for attaching handles to a border material for a mattress. The system includes a pair of sewing heads movably mounted along a sewing area. The sewing heads can be moved from a first position for sewing the handles to the border in a first orientation, such as a horizontal orientation extending along the length of the border, to a second position for sewing the handles to the border in a different orientation, such as a vertical orientation extending across the width or height of the border.

Abstract: An automatic panel cutting and edge seaming system includes a series of side edge cutting and seaming assemblies that receive a fabric material and trim and sew seams along the side edges of the fabric material to form a desired width panel. Puller rolls pull the material through the side edge cutting and seaming assemblies and feed the trimmed and seamed fabric material to a cross-cut sewing assembly. After a sufficient length of fabric material has been fed to form a desired size panel, the cross-cut sewing assembly is engaged to cut and seam the end of the panel.

Abstract: A system for automatically attaching a flanging material to the edges of a panel such as for a mattress, including a work table on which the panel is supported and a sewing assembly having a sewing machine located along a path of travel of the panel across the work table. The flanging material is fed from a supply of flanging material located adjacent the sewing assembly, and is attached to the side edges and about the corners of the panel by the sewing machine of the sewing assembly. A clamp mechanism engages and holds the panel as the sewing machine of the sewing assembly attaches the flanging material about the corners of the panel.

Abstract: A system for automatically stretching and stapling a foundation cover to a spring unit for a foundation, including a support table for supporting the foundation and cover, and a series of stretching/stapling assemblies or units positioned along the support table. The stretching/stapling assemblies include a series of tension applicators that engage and pull the cover taut against the sides of the spring unit of the foundation, while staplers are lowered into engagement with the cover and foundation frame, automatically stapling the cover to the sides of the foundation frame.

Abstract: An automatic panel cutting and edge seaming system includes a series of side edge cutting and seaming assemblies that receive a fabric material and trim and sew seams along the side edges of the fabric material to form a desired width panel. Puller rolls pull the material through the side edge cutting and seaming assemblies and feed the trimmed and seamed fabric material to a cross-cut sewing assembly. After a sufficient length of fabric material has been fed to form a desired size panel, the cross-cut sewing assembly is engaged to cut and seam the end of the panel.

Abstract: An apparatus for attaching a gusset to a panel includes a gusset folder that receives and folds a gusset material to form the gusset. The panel is supported by a sewing table. A sewing machine is positioned relative to the sewing table so as to be able to sew the gusset to the panel. A gusset guide guides the gusset toward a selected edge of the panel so that the gusset is held in substantial alignment with the edge of the panel. An edge detector detects when a next edge of the panel is approaching the sewing machine. A turning mechanism is positioned along the sewing table and is moveable into engagement with the panel. The turning mechanism turns the panel relative to the sewing machine when the edge detector detects the next edge of the panel is approaching the sewing machine.

Abstract: An apparatus for attaching a gusset to a panel includes a gusset folder that receives and folds a gusset material to form the gusset. The panel is supported by a sewing table. A sewing machine is positioned relative to the sewing table so as to be able to sew the gusset to the panel. A gusset guides the gusset toward a selected edge of the panel so that the gusset is held in substantial alignment with the edge of the panel. An edge detector detects when a next edge of the panel is approaching the sewing machine. A turning mechanism is positioned along the sewing table and is moveable into engagement with the panel. The turning mechanism turns the panel relative to the sewing machine when the edge detector detects the next edge of the panel is approaching the sewing machine.

Abstract: An automatic border sewing system having a pre-feed assembly for feeding a length of material for forming a mattress border. A feed and cut assembly feeds the border material into a sewing station for forming mitered corners in the border material and thereafter cuts the border material to form a border of a desired length. The mitered border is moved to a closer station for closing the leading and trailing edges of the border.

Abstract: An automatic border sewing system having a pre-feed assembly for feeding a length of material for forming a mattress border. A feed and cut assembly feeds the border material into a sewing station for forming mitered corners in the border material and thereafter cuts the border material to form a border of a desired length. The mitered border is moved to a closer station for closing the leading and trailing edges of the border.

Abstract: A machine for automatically producing a mattress border with handles sewn to the border material. Border material is pre-fed from a selected spool, screened for splice avoidance and measured. Handle material is fed from a selected spool mounted in a multiple handle material spool magazine mounted on rails, fed into a handle folding assembly, and cut to length. Ends of the handle material are folded under by the handle folding assembly and the handle then transferred in a folded condition from the handle folding assembly to a correct position on the border material. A double frame handle press holds each folded end of the handle material in place as each end is maneuvered under a sewing head needle to apply a stitch pattern to secure the folded ends to the border material. The double frame handle press is translated separately from the carriage assembly which travels in the sew pattern, to position the other end of the handle under the sewing needle.

Abstract: A machine for automatically producing a mattress border with handles sewn to the border material. Border material is pre-fed from a selected spool, screened for splice avoidance and measured. Handle material is fed from a selected spool mounted in a multiple handle material spool magazine mounted on rails, fed into a handle folding assembly, and cut to length. Ends of the handle material are folded under by the handle folding assembly and the handle then transferred in a folded condition from the handle folding assembly to a correct position on the border material. A double frame handle press holds each folded end of the handle material in place as each end is maneuvered under a sewing head needle to apply a stitch pattern to secure the folded ends to the border material. The double frame handle press is translated separately from the carriage assembly which travels in the sew pattern, to position the other end of the handle under the sewing needle.

Abstract: A sewing system (10) includes a tension adjustment spindle assembly (30) constructed and arranged to move a spindle (26) laterally toward and away from a sewing head (16) of the sewing machine to adjust the tension in the looped end of a work piece (28). A tension roller (70) engages a bottom run (29) of the work piece (28), so that when proper tension is applied to the work piece at the beginning of the cycle of operation by the lateral shifting of the tension adjustment spindle assembly (30), a proximity switch (88) detects the upward movement of a tension arm (72) and initiates the operation of the sewing system.

Abstract: A textile fold control system (40) includes a hem engager (46) mounted to a downstream side of a sewing machine (42), and a roller (76) for engaging and moving a hem formed in a textile work piece slightly downward so as to bend the hem about a trailing edge (79) of a work surface (54) of the sewing machine, thereby applying increased frictional contact between an edge portion (88) of the work piece and the work surface, and additional surface-to-surface contact between the edge portion and an adjacent body portion (90) of the hem in order to avoid the curling or unfolding of the hem during a pre-feed portion of the sewing cycle of the sewing machine.

Abstract: A guiding system for use with translucent textile work pieces is disclosed. A free edge (52) of a tubular work piece extends along a continuous processing path and is folded under the work piece to form a hem in the work piece. The work piece is then advanced along the processing path toward a downstream sewing machine (11), whereupon the hem is sewn in the work piece. A lower ply sensing opposed beam sensor (76) upstream of the sewing machine detects a multiple ply leading edge of the folded hem, and is moved by a pneumatic cylinder (88) into a position laterally with respect to the processing path where it will detect the free edge of the folded and sewn hem, and will control a lower work piece guide assembly (34) so as to maintain a proper depth of the hem. This enables the sewing needles (20) of the sewing machine to align the two spaced parallel lines of stitching (68) at the beginning and end of the hem line for minimizing waste in such hem forming operations.