Abstract: An apparatus for assembling a bedding foundation having spring modules and a frame includes a support configured to receive the frame, a bridge disposed over the support, and staplers movably coupled to the bridge and positioned over the support, each stapler configured to staple a spring module to the frame. The apparatus also includes cameras coupled to the bridge and positioned over the support. Each stapler is operatively associated with one of the cameras and each camera is positioned to provide a field of view toward the support. The apparatus also includes 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.

Abstract: An apparatus for assembling a bedding foundation having spring modules and a frame includes a support configured to receive the frame, a bridge disposed over the support, and staplers movably coupled to the bridge and positioned over the support, each stapler configured to staple a spring module to the frame. The apparatus also includes cameras coupled to the bridge and positioned over the support. Each stapler is operatively associated with one of the cameras and each camera is positioned to provide a field of view toward the support. The apparatus also includes 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.

Abstract: Systems and methods for producing bedding products by remotely directing the operation of a bedding machine are provided. Embodiments include a system and a method for wirelessly controlling a bedding machine via a remote human machine interface on a mobile device. In some embodiments, the remote human machine interface is configured to provide notifications and alerts and to receive user input to remotely facilitate the operation and maintenance of a bedding machine.

Abstract: A method of dynamically changing stitch density of a quilting pattern during sewing is provided. Embodiments of the invention include dynamically changing stitch density along an axis of a sewing pattern based on identifying sewing pattern elements, which may include line segments and arc segments. Each of the line segments and/or arc segments is assigned a dynamically adjusted stitch density based on analysis of each pattern element and/or adjacent element. An adjusted stitch density is assigned to portions of pattern elements that satisfy a threshold measurement for sewing with an adjusted stitch density. In embodiments, a standard stitch density, intermediate stitch density, or an altered stitch density is automatically assigned to each portion of a sewing pattern based on an analysis of threshold length of an element, a threshold angle of a portion of the element with respect to the axis, and/or the stitch density assigned to an adjacent element.

Abstract: Systems and methods for producing bedding products by remotely directing the operation of a bedding machine are provided. Embodiments include a system and a method for wirelessly controlling a bedding machine via a remote human machine interface on a mobile device. In some embodiments, the remote human machine interface is configured to provide notifications and alerts and to receive user input to remotely facilitate the operation and maintenance of a bedding machine.

Abstract: A method of dynamically changing stitch density of a quilting pattern during sewing is provided. Embodiments of the invention include dynamically changing stitch density along an axis of a sewing pattern based on identifying sewing pattern elements, which may include line segments and arc segments. Each of the line segments and/or arc segments is assigned a dynamically adjusted stitch density based on analysis of each pattern element and/or adjacent element. An adjusted stitch density is assigned to portions of pattern elements that satisfy a threshold measurement for sewing with an adjusted stitch density. In embodiments, a standard stitch density, intermediate stitch density, or an altered stitch density is automatically assigned to each portion of a sewing pattern based on an analysis of threshold length of an element, a threshold angle of a portion of the element with respect to the axis, and/or the stitch density assigned to an adjacent element.

Abstract: A method of testing a sleep support member, the method including: identifying the sleep support member; determining a tested comfort/support value for the identified sleep support member before the identified sleep support member is provided to a customer; and determining whether the tested comfort/support value is within a predetermined tolerance level of a goal comfort/support value for the identified sleep support member. An apparatus for testing a sleep support member, the apparatus including: an identification unit configured to identify the sleep support member; a comfort/support testing unit configured to determine a tested comfort/support value for the identified sleep support member before the identified sleep support member is provided to a customer; and an analysis unit configured to determine whether the tested comfort/support value is within a predetermined tolerance level of a goal comfort/support value for the identified sleep support member.

Abstract: A method of testing a sleep support member, the method including: identifying the sleep support member; determining a tested comfort/support value for the identified sleep support member before the identified sleep support member is provided to a customer; and determining whether the tested comfort/support value is within a predetermined tolerance level of a goal comfort/support value for the identified sleep support member. An apparatus for testing a sleep support member, the apparatus including: an identification unit configured to identify the sleep support member; a comfort/support testing unit configured to determine a tested comfort/support value for the identified sleep support member before the identified sleep support member is provided to a customer; and an analysis unit configured to determine whether the tested comfort/support value is within a predetermined tolerance level of a goal comfort/support value for the identified sleep support member.