An apparatus for securing a plurality of modules to a frame, the apparatus comprising: a base for supporting a frame and a wire grid including a plurality of modules; a support; a drive mechanism coupled to at least one of the support and the base, the drive mechanism being configured to provide relative movement between the support and the base; a controller coupled to the drive mechanism; a tool coupled to the support, the tool being configured to secure each module to the frame; at least one sensor configured to locate a portion of the wire grid without the use of a vision guidance system, the at least one sensor providing feedback signals to the controller; and a mechanical guide coupled to the tool, the mechanical guide being configured to engage the module as the tool and the mechanical guide move relative to the module so that the tool and the module are aligned at a target fastening location. view more

A method of forming a portion of a box spring or mattress foundation, the method comprising: providing a base; locating a wood frame on the base, the wood frame including a plurality of spaced apart, generally parallel frame sections; locating a wire grid including a plurality of modules arranged in a plurality of rows on the frame, each row including a plurality of modules formed from a continuous metal wire with each module having a top portion spaced apart from the frame, first and second side portions extending downwardly from the top portion, and a bottom portion connecting the first and second side portions, the bottom portion being positioned on one of the frame sections; locating a stapler above the base; providing a mechanical guide on the stapler; sensing the location of a portion of the wire grid without the use of a vision guidance system; moving the stapler and the mechanical guide relative to the base, the mechanical guide engaging the module so that both the stapler and the module are aligned at a target fastening location on the frame section; and inserting a staple from the stapler over the bottom portion the module and into the frame section at the target fastening location. view more

A method of forming a portion of a box spring or mattress foundation, the method comprising: providing a base; locating a wood frame on the base, the wood frame including a plurality of spaced apart, generally parallel frame sections; locating a plurality of modules arranged in a plurality of rows on the frame, each row including a plurality of modules formed from a continuous metal wire with each module having a top portion spaced apart from the frame, first and second side portions extending downwardly from the top portion, and a bottom portion connecting the first and second side portions, the bottom portion being positioned on one of the frame sections and the first and second side portions of the module being spaced apart to define an open access area above the bottom portion; locating a fastening tool above the base; providing a module alignment device; moving the module with the module alignment device; moving the fastening tool without the use of a vision guidance system in a direction generally perpendicular relative to the base and through the open access area of a module until the fastening tool is located at a target fastening location; and securing the bottom portion of the module to the frame at the target fastening location with the fastening tool. view more

A method of forming a portion of a box spring or mattress foundation, the method comprising: providing a base; locating a wood frame on the base, the wood frame including a plurality of frame sections; locating a plurality of spring modules above the frame, each module having a bottom portion positioned on one of the frame sections; locating a fastening tool above the base, the fastening tool being initially spaced apart from the plurality of spring modules and the frame; providing a module alignment device; moving the module with the module alignment device to compensate for misalignment of the module relative to at least one of the frame section and the fastening tool; moving the fastening tool relative to the base, the plurality of spring modules and the frame without the use of a vision guidance system until the fastening tool is located at a target fastening location; and securing the bottom portion of the module to the frame at the target fastening location with the fastening tool. view more

An apparatus for securing a plurality of modules to a frame to form a portion of a box spring or mattress foundation, each module including first and second side portions and a bottom portion coupled to the first and second side portions, the bottom portion being located on the frame, the first and second side portions of the module being spaced apart to define an open access area above the bottom portion, the apparatus comprising: a base configured to support the frame and the plurality of modules; a fastening tool located above the base and initially spaced apart from the plurality of modules and the frame, the fastening tool being configured to secure the bottom portion of a module to the frame; a module alignment device configured to engage the module to move the module to compensate for misalignment of the module relative to at least one of the frame section and the fastening tool; and a drive mechanism configured to move the fastening tool relative to the base, the plurality of spring modules and the frame in a direction generally perpendicular to the base without the use of a vision guidance system, the fastening tool moving through the open access area of a module to a target fastening location to permit the fastening tool to secure the bottom portion of the module to the frame at the target fastening location. view more

An apparatus for securing a plurality of modules to a frame to form a portion of a box spring or mattress foundation, each module including first and second side portions and a bottom portion coupled to the first and second side portions, the bottom portion being located on the frame, the apparatus comprising: a base configured to support the frame and the plurality of modules; a stapler located above the base, the stapler being configured to place a staple over the bottom portion of a module and into the frame; a drive mechanism configured to provide relative movement between the stapler and the base; and a mechanical guide configured to engage the module as the mechanical guide moves relative to the module, engagement of the mechanical guide with the module causing relative movement between the stapler and the module so that the stapler and the module are aligned at a target fastening location to permit the stapler to place a staple over the bottom portion of the module and into the frame at the target fastening location. view more

The apparatus of claim 1, wherein the mechanical guide includes first and second portions which are each configured to define an opening to receive the first and second side portions of the module, respectively, as the mechanical guide moves relative to the module. view more