Abstract: A welding head employs a carriage assembly for guiding the welding head along a track or guide. A torch assembly, mounted on the carriage assembly, is configurable for multiple welding processes. The torch assembly includes a torch block and a GTA filler wire guide mounted together on a mounting plate, whereby the GTA filler wire guide is placed in general proximity of a welding torch mounted on the torch block. The torch block accommodates the mounting of either of a GMA torch and a GTA torch. Additionally, the torch block accommodates placement of a GMA adapter sleeve within the torch block to feed a filler wire through the GMA torch. A system control unit provides manual, semi-automated, or automated control of welding system resources including a welding power supply, a supply of one or more shielding gasses, and a fluid coolant supply.

Abstract: A method and apparatus are provided for sewing handles lengthwise on a strip of mattress border material or other elongated strip of material. A fold is formed and aligned on a leading end of handle stock and is advanced to a sewing head where the fold is sewn to the strip of material. The handle stock is then cut at a point to leave the proper length of handle stock to form the handle and a fold is formed in the trailing end of the handle, aligned and positioned at the sewing head where it is sewn to the strip material to complete the handle. All of the above are performed automatically under programmable control.

Abstract: A method and apparatus for sewing flange material to a fabric panel, preferably the top or bottom panel of a mattress sack. The apparatus includes a sled which pulls the fabric panel to and through the sewing machine. The apparatus also includes an edge guide that guides one edge of the panel to the sewing machine as well as provides a thickness measurement of the panel and smooths the fabric panel prior to sewing. The apparatus also includes a moveable dolly which carries the sewing machine find the flange material, and a wheel which engages the fabric panel during movement of the sewing machine away from the fabric panel to prevent movement of the fabric panel. The apparatus also includes apparatus for automatically removing the fabric panel from the table after completion of the sewing operation, as well as a cutter for cutting the trailing flange material and the sewing threads.

Abstract: A method and apparatus for stitching a label to material in which the material and label are joined face side down rather than face side up. The label is held face side down with a clamp and a panel is held over the label by a clamp. The label and panel are joined by a sewing machine. Further, a mechanism is provided for activating a thread knife of the sewing machine at such a time that the bobbin thread only is cut. A masking mechanism is provided for masking electronic signals of the sewing machine that would otherwise cause the machine to reset at a normal needle height, so that a sewing operation can be stopped with a needle at a maximum clearance position. Pneumatic cylinders and linkage are provided for raising the needle and presser foot at the end of a stitching operation.

Abstract: Sewing apparatus for joining a first panel and a second panel and having an arm that is rotated about an axis normal to the surface of the first panel to rotate the first panel, a shoe biased to follow an edge of the first panel as the first panel is fed to the sewing machine, a detector to monitor the shoe and provide a signal indicative of a longitudinal orientation of the edge of the first panel, and means for adjusting the longitudinal orientation of the first panel with respect to a true feed direction in response to the longitudinal orientation signal. An edge flattener including a generally cylindrical component is provided.

Abstract: An improved method and apparatus for the assembly of pillow-top mattress covers. In the method of this invention, the gussets for a pillow-top mattress cover are prepared in a single step in which the gusset material is folded longitudinally, and the flange material is attached thereto and the gusset material is sewn together in one stitch. Thereafter, a gusset is attached to each of the top and bottom panels of the cover along its outer edge. Each gusset is secured to the underside of its associated top or bottom panel at the folded edge using a blind stitch which is not visible externally of the panel. No gluing is required. During the step of attaching the gusset to its associated mattress cover panel, precisely positioned mitered corners are formed on the gusset where the gusset is to be attached to the corner of its associated panel.

Abstract: A method and apparatus for sewing a cloth handle to the side panel of a mattress or box spring. The apparatus includes a modified X-Y programmable sewing machine which can sew both ends of a handle to the side panel in sequence without the necessity of removing the handle and side panel from the clamp and manually adjusting the position of the side panel. The apparatus also includes a folding jig, and a clamp with an upper lip to retain the handle in a desired position. The method includes the steps of folding the handle and placing it within the clamp on the sewing machine, and thereafter sequentially stitching each end of the handle to the side panel automatically without removing the handle from the clamp or without manual movement of the side panel.

Abstract: A process for buttwelding metal workpieces having bevelled joint preparations using an automatic GTAW welder using filler wire includes preparing the bevelled workpiece with bevelled joint areas having minimal land thickness at the root extremities; placing the prepared workpiece joint sections together with an open gap between their adjacent root extremities, the gap having a minimum dimension that avoids harmful compression stress between the workpieces due to weld shrinkage and a maximum dimension that avoids filler wire penetration of the gap; fusion welding the open root area of the adjacent workpieces with a root pass weld using an automatic GTAW welder supplied with filler wire and a shield gas including 1 to 10% hydrogen and the balance inert gas; and then promptly overlaying the root pass weld with at least one additional filler weld pass using an automatic GTAW supplied with filler wire and hydrogen-free shield gas.

Abstract: A method and apparatus for forming a partial mattress sack which prevents radial bunching of the mattresses. The method includes the steps of feeding first and second panels having different edge lengths at different rates through a sewing machine to form the partial mattress sack. The apparatus includes a variable speed upper walking foot having an automatic speed adjustment.

Abstract: A method and apparatus for forming a side panel for a mattress sack or a box spring enclosure. The apparatus includes a double needle sewing machine and a guide for the ends of the folded side panel which are being stitched together which aligns and guides the ends through the stitching area. Photocells are provided to start and stop the stitching process. The method includes the step of stopping the stitching process after a predetermined number of stitches if light from a second photocell in the feed direction is not interrupted within a predetermined number of stitches.

Abstract: An improved method and apparatus for the assembly of pillow-top mattress covers. In the method of this invention, the gussets for a pillow-top mattress cover are prepared in a single step in which the gusset material is folded longitudinally, and the flange material is attached thereto and the gusset material is sewn together in one stitch. Thereafter, a gusset is attached to each of the top and bottom panels of the cover along its outer edge. Each gusset is secured to the underside of its associated top or bottom panel at the folded edge using a blind stitch which is not visible externally of the panel. No gluing is required. During the step of attaching the gusset to its associated mattress cover panel, precisely positioned mitered corners are formed on the gusset where the gusset is to be attached to the corner of its associated panel.

Abstract: A method and apparatus for maniuplating and sewing first and second panels together is disclosed including a rotatable arm for rotating a first panel and control means for reducing the stitching speed in response to detection of a comer of the first panel.

Abstract: A method for forming a partial mattress sack which prevents radial bunching includes feeding first and second panels having different edge lengths at different rates through a sewing machine to form the partial mattress sack. An apparatus for sewing the partial mattress sack includes a mechanism for driving upper and lower walking feet at varying rates and a mechanism for driving the upper walking foot at the same speed as a second lower walking foot.

Abstract: A sewing machine apparatus and method for sewing a label to a thick, puffy, or quilted mattress is disclosed. The apparatus includes a pair of clamps attached to a carriage, a cutter and nipper disposed above the carriage, and a controller for controlling the sewing machine and carriage.

Abstract: An improved method and apparatus for the assembly of pillow-top mattress covers. In the method of this invention, the gussets for a pillow-top mattress cover are prepared in a single step in which the gusset material is folded longitudinally, and the flange material is attached thereto and the gusset material is sewn together in one stitch. Thereafter, a gusset is attached to each of the top and bottom panels of the cover along its outer edge. Each gusset is secured to the underside of its associated top or bottom panel at the folded edge using a blind stitch which is not visible externally of the panel. No gluing is required. During the step of attaching the gusset to its associated mattress cover panel, precisely positioned mitered corners are formed on the gusset where the gusset is to be attached to the corner of its associated panel.

Abstract: The invention comprises improvements to sewing machines for increasing the throat clearance of the machine. The improvements relate to 1) modifications to mechanical components of the machine to increase the throw and upper travel limits of the presser foot, upper feeding foot, needle and spreader, 2) an adjustment for allowing the speed of the upper walking foot to be variable relative to the speed of the lower walking foot, and 3) an improved biasing spring for biasing the presser foot downward.

Abstract: An improved method and apparatus is provided for use in a sewing machine. The improvements include preloading two pieces of material which are to be sewn together. The preloading is accomplished by positioning pieces of material to be sewn under a gripper spaced from the sewing head on a table while prior pieces of material are being sewn. The gripper engages the material and, when the prior sewing operation is completed, the gripper is moved across the table toward the sewing head to load the preloaded pieces of material. When the two pieces of material are preloaded, most of the material hangs over an edge of the table and the lengths of the pieces of material are determined by movable detectors.

Abstract: A method and apparatus are provided for aligning one or more plies of material moving in a predetermined direction, and preferably through a desired path of travel, prior to stitching in a sewing machine. A friction wheel or other guide element is provided for applying a force to the ply having a component in a direction transverse to the direction of travel and sensors are provided for sensing the transverse position of the ply at the point where the sensor is located relative to the desired transverse position at that point. The sensor outputs are weighted, and where two or more sensors are provided, the sensor outputs are combined in a predetermined manner. The combined and weighted outputs are then utilized to control the transverse force applied by the guide element to the ply. The operating speed of the sewing machine may be utilized either as an additional input to control transverse force or to control the rate at which adjustments are made to the transverse force.

Abstract: In a sewing machine, a clamp-type work feeder includes an articulated, rotatable, telescoping tube carriage which can move in either direction parallel to the lower arm and rotate about the axis of the cylindrical end of the lower arm in accordance with a stored stitch program. A cylinder actuated clamp mechanism pivotally attached to the carriage allows simple work insertion and full peripheral stitching without unduly obstructing the operator's view or access to the stitching area.

Abstract: In a sewing machine for performing twin overedging and seaming in one high-speed operation, specially designed top and bottom variable feed dogs pull the two plies through a three needle stitching area with improved, simplified elements for diverting one ply edge while the other is being overcast. The upright overcast edge of the top ply passes through a tunnel formed through the top feed dog. A guide wall attached to the throat plate guides the top edge away from the bottom overedging station. A guard wall can be attached to the presser foot to keep the turned-up top edge away from the seaming needle. A fiber optic/pneumatic system controls automatic stop, presser foot/top feed retraction and between-work thread cutter functions. Alternative front edge guides facilitate feeding the two plies in registration.