Abstract: A spring coil assembly having a first row of coils arranged in a first spacing pattern and a second row of coils adjacent the first row and arranged in a second spacing pattern that is different from the first spacing pattern. The spring coil assembly can be assembled using an apparatus comprising a main conveyor adapted to convey a plurality of coils along an axis, an assembler which is operable to intertwine a plurality of coils into a spring coil assembly, and a transfer station operable to move a plurality of coils from the main conveyor into the assembler. The transfer station includes a plurality of pusher arms each of which include a gripper which is operable to grasp an individual coil, a carriage supporting the gripper arms and means for shifting the carriage axially relative to the axis so that a plurality of coils carried by the gripper arms are displaced in the direction of travel of the conveyor.

Abstract: An apparatus for assembling coil springs together into a matrix of coil springs. The apparatus has workholders with respective grippers that receive and hold portions of end turns of respective coil springs, and a loader supporting the workholders for moving the workholders through a motion that transfers the respective coil springs from a conveyor to the apparatus. The coil assembling apparatus has, for each coil, a die set having a fixed die and a movable die. The movable die is connected to a drive via linkage. The drive is operable to move the movable die through a motion that maintains a planar die face of the movable die substantially parallel to a planar die face of the stationary die. The coil assembling apparatus is also operable to automatically assemble two rows of coil springs into a row of coaxial coil springs.

Abstract: An apparatus for assembling coil springs together into a matrix of coil springs. The apparatus has workholders with respective grippers that receive and hold portions of end turns of respective coil springs, and a loader supporting the workholders for moving the workholders through a motion that transfers the respective coil springs from a conveyor to the apparatus. The coil assembling apparatus has, for each coil, a die set having a fixed die and a movable die. The movable die is connected to a drive via linkage. The drive is operable to move the movable die through a motion that maintains a planar die face of the movable die substantially parallel to a planar die face of the stationary die. The coil assembling apparatus is also operable to automatically assemble two rows of coil springs into a row of coaxial coil springs.

Abstract: Machinery for automated manufacture of formed wire structures such as innerspring assemblies for mattresses and seating and flexible support structures includes one or more coil formation devices configurable to produce helical spring coils having a terminal convolution which extends beyond an end of the coil; a conveyor system having a plurality of flights slidably mounted upon a continuous track and connected to a chain and driven by an index driver, the flights being connected to a drive system which enables variable spacing between the flights so that the conveyor can be loaded with articles at one spacing interval and be unloaded at a different interval; a coil transfer machine which removes a row of coils from the conveyor and inserts the coils into an innerspring assembler; an innerspring assembler having first and second sets of coil-engaging dies in a parallel arrangement, each set of dies having an upper row positioned over a lower row, the dies being mounted upon carrier bars which are vertically t