An automated spring wire forming device having a guide structure and methods of using the same

Abstract

The application discloses an automatic spring steel wire forming device with a guide structure and a use method thereof, relates to the technical field of spring forming, and comprises a wire feeding mechanism, a pre-straightening and online detection module, a positive flexible guide module, a force feedback forming module and a central control system; the pre-straightening and online detection module, the positive flexible guide module and the force feedback forming module are sequentially connected in series along a feeding path of the steel wire and are electrically connected with the central control system; the positive flexible guide module is internally provided with a precision actuator controlled by the central control system; the force feedback forming module comprises a forming component and a force sensor connected with the forming component, and the force sensor is used for feeding real-time forming force in a forming process to the central control system. Through closed-loop control of online sensing, active guiding and force feedback, intelligent adaptation to parameter changes of the steel wire is realized, and the precision, consistency, reliability and service life of the spring forming device are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of spring forming technology, specifically to an automated spring steel wire forming device with a guiding structure and its usage method. Background Technology

[0002] As a widely used basic component in industrial systems, the quality and performance of springs directly affect the stability and reliability of the entire equipment or product. Spring wire forming equipment is the core equipment in spring production, and its technological level determines the geometric accuracy, mechanical properties, and production efficiency of the springs. In the context of automated production, the spring manufacturing industry has placed higher demands on forming equipment, especially when dealing with high-strength, high-elasticity spring wires. Ensuring the dimensional consistency and performance stability of each product during high-speed processing has become a continuously pursued technological goal in this field. Traditional forming processes mainly rely on fixed, passive mechanical structures to guide and form the wire. While this method can meet basic requirements when handling standard materials under ideal conditions, its limitations become increasingly apparent when facing fluctuations in the physical parameters of incoming materials in actual production. It struggles to meet the comprehensive requirements of modern precision manufacturing for high efficiency, high yield, and high stability.

[0003] Existing technologies suffer from a series of inherent contradictions and defects in practical applications. First, there is a serious conflict between production speed and forming accuracy. Increasing wire feeding speed to improve production efficiency inevitably exacerbates the vibration and inertial effects of the high-elasticity steel wire, leading to unstable motion trajectories and severely affecting the accuracy of key geometric dimensions such as spring diameter and pitch. This makes it difficult to achieve both high-speed production and high-precision forming simultaneously. Second, there is a contradiction between the rigid constraints and flexible adaptation of the guide structure. Precise guidance requires a very small gap between the guide component and the steel wire, demanding high rigidity from the guide structure. However, this fixed rigid structure cannot accommodate the diameter tolerances inherent in the steel wire itself, nor can it handle the switching needs of different batches and specifications of steel wire, lacking the necessary flexible adjustment capabilities. Finally, it is difficult to balance the wear resistance of components with manufacturing costs. High-speed movement of the steel wire through the guide structure generates intense friction, leading to rapid wear of the guide components. Using expensive ultra-wear-resistant materials to improve durability significantly increases the manufacturing and maintenance costs of the equipment, placing a heavy economic burden on users. These fundamental flaws collectively lead to problems such as poor consistency of finished products, limited production efficiency, short lifespan of key components, and strong dependence on operator experience in existing equipment. Summary of the Invention

[0004] The purpose of this invention is to provide an automated spring steel wire forming device with a guiding structure and its usage method, thereby solving the problems existing in the background art.

[0005] To solve the above-mentioned technical problems, the present invention provides an automated spring steel wire forming device with a guiding structure, comprising: a wire feeding mechanism, a pre-straightening and online detection module, an active flexible guiding module, a force feedback forming module, and a central control system;

[0006] The pre-alignment and online detection module, the active flexible guidance module, and the force feedback forming module are sequentially connected in series along the feed path of the steel wire.

[0007] The pre-calibration and online detection module, the active flexible guidance module, and the force feedback forming module are all electrically connected to the central control system via a data bus.

[0008] The pre-calibration and online detection module is used to detect the physical parameters of the steel wire and send them to the central control system;

[0009] The active flexible guide module is equipped with a precision actuator controlled by the central control system. The precision actuator is used to drive the guide block to move, so as to dynamically adjust the guide gap provided to the steel wire.

[0010] The force feedback molding module includes a molding component and a force sensor connected to the molding component. The force sensor is used to feed back the real-time molding force during the molding process to the central control system.

[0011] Preferably, the pre-straightening and online detection module includes a multi-directional straightening wheel, a non-contact sensor for measuring the diameter of the steel wire, and an eddy current sensor for detecting the material of the steel wire; wherein the non-contact sensor and the eddy current sensor are both electrically connected to the central control system.

[0012] Preferably, the non-contact sensor is a laser biaxial diameter measuring instrument.

[0013] Preferably, the active flexible guide module includes at least two sets of guide units arranged along the direction of movement of the steel wire; the guide unit includes at least a pair of guide blocks arranged opposite each other, the guide blocks together forming a guide hole for constraining the steel wire; the precision actuator is connected to the guide block and is used to drive the guide block to move relative to each other to change the size of the guide hole.

[0014] Preferably, the opposite surfaces of the guide block are made of an ultra-wear-resistant, low-friction material.

[0015] Preferably, the precision actuator is a piezoelectric ceramic actuator or a micro servo motor.

[0016] Preferably, the forming component includes a bending pin, a pitch gauge, and a cutter.

[0017] Preferably, the force sensor is a piezoelectric force sensor or a strain gauge force sensor, and is used to connect the molding component to the device frame.

[0018] A method of using an automated spring steel wire forming device with a guiding structure includes the following steps:

[0019] S1. Online detection and data transmission: First, the steel wire is fed into the pre-straightening and online detection module (200) by the wire feeding mechanism (100). This module performs preliminary straightening of the steel wire and detects its physical parameters such as diameter and material through non-contact sensors (202) and eddy current sensors (203). These parameters are then sent to the central control system (500) as real-time data.

[0020] S2. Active guidance control: The central control system (500) performs calculations based on the received real-time wire diameter data and preset process parameters, and sends control commands to the active flexible guidance module (300) to drive the precision actuator (301) inside it. Before the wire arrives, the guide gap between the guide blocks (302) is dynamically adjusted to provide a precisely matched guide channel for the wire.

[0021] S3, Force Feedback Closed-Loop Forming: The precisely guided steel wire enters the force feedback forming module (400). While the forming component (401) performs forming actions such as bending and cutting, the forming force is monitored in real time by the force sensor, and the force data is fed back to the central control system (500).

[0022] S4. Compensatory adjustment: The central control system (500) compares the real-time forming force with the preset standard process force value model. When the force value deviation exceeds the threshold, the closed-loop feedback control algorithm is activated to fine-tune the wire feeding speed of the wire feeding mechanism (100) or the movement of the forming component (401) to compensate for the influence of the fluctuation of the physical properties of the steel wire.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] Through an integrated intelligent control system, the physical parameters of spring steel wire are perceived in real time. Before the wire enters the core processing area, the system can accurately obtain key information such as its diameter and use this dynamic data as the basis for decision-making in all subsequent control links. This gives the device predictive capabilities and allows it to prepare the optimal processing strategy in advance for the unique properties of each inch of wire, thus laying a solid data foundation for achieving high-precision adaptive forming.

[0025] A flexible guiding system capable of proactive micron-level dynamic adjustment has been developed. Based on the real-time detection of the steel wire diameter upstream, the gap of the guiding channel can be automatically adjusted to an ideal state just before the steel wire arrives. This provides stable and precise path constraints for the high-speed moving steel wire, effectively suppressing vibration and minimizing the severe friction and impact caused by interference fit. It integrates the precision of high rigidity constraints with the adaptability of flexible adjustment, significantly improving the forming accuracy of the equipment under high-speed operation and its adaptability to material tolerances.

[0026] By setting a force feedback module at the forming end, a closed-loop control of the forming process is constructed. When bending or cutting the steel wire, the magnitude of the forming force can be monitored in real time and compared with the standard process model. Once the actual force value deviates due to factors such as material hardness fluctuations, the control system will immediately make compensatory fine adjustments to the wire feeding or forming parameters. This ensures that even if there are differences in the mechanical properties of the incoming materials, each spring product produced can still maintain a high degree of consistency in key geometric parameters, fundamentally improving the overall quality and reliability of the product. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of the overall structure of the device;

[0029] Figure 2 This is a structural diagram of the wire feeding mechanism and the pre-calibration and online detection module;

[0030] Figure 3 This is a schematic diagram of the connection structure of the guide block;

[0031] 100. Wire feeding mechanism; 200. Pre-straightening and online detection module; 201. Multi-directional straightening wheel; 202. Non-contact sensor; 203. Eddy current sensor; 300. Active flexible guide module; 301. Precision actuator; 302. Guide block; 400. Force feedback forming module; 401. Forming component; 500. Central control system. Detailed Implementation

[0032] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0033] Please see Figure 1-3 The present invention provides an automated spring steel wire forming device with a guiding structure, comprising: a wire feeding mechanism 100, a pre-straightening and online detection module 200, an active flexible guiding module 300, a force feedback forming module 400, and a central control system 500.

[0034] The pre-alignment and online detection module 200, the active flexible guide module 300, and the force feedback forming module 400 are sequentially connected in series along the feed path of the steel wire.

[0035] The pre-calibration and online detection module 200, the active flexible guidance module 300, and the force feedback forming module 400 are all electrically connected to the central control system 500 via a data bus.

[0036] The pre-calibration and online detection module 200 is used to detect the physical parameters of the steel wire and send them to the central control system 500;

[0037] The active flexible guide module 300 is internally equipped with a precision actuator 301 controlled by the central control system 500. The precision actuator 301 is used to drive the guide block 302 to move, so as to dynamically adjust the guide gap provided to the steel wire.

[0038] The force feedback molding module 400 includes a molding component 401 and a force sensor connected to the molding component 401. The force sensor is used to feed back the real-time molding force during the molding process to the central control system 500.

[0039] This technical solution provides an automated spring steel wire forming device with a guiding structure. Traditional spring steel wire forming devices struggle to balance processing speed and forming accuracy during the process. The fixed guiding structure cannot accommodate the diameter tolerance of the steel wire, and high-speed friction causes severe wear. This device aims to solve the above-mentioned technical problems.

[0040] In operation, the device consists of a wire feeding mechanism 100, a pre-straightening and online detection module 200, an active flexible guide module 300, and a force feedback forming module 400, arranged sequentially along the wire feeding path. All modules are electrically connected and exchange information with a central control system 500 via a data bus. The workflow is as follows: First, the wire is fed into the pre-straightening and online detection module 200 by the wire feeding mechanism 100. This module performs preliminary straightening of the wire and detects its diameter, material, and other physical parameters, sending these parameters as real-time data to the central control system 500. The central control system 500 then processes the received real-time data... The system calculates based on preset process parameters and sends control commands to the active flexible guide module 300. This guide module dynamically adjusts its internal guide gap according to the commands, providing a precisely matched guide channel for the steel wire. Subsequently, the precisely guided steel wire enters the force feedback forming module 400. While performing the forming action, this module monitors the forming force in real time through a force sensor and feeds the force data back to the central control system 500. Based on this feedback, the central control system 500 performs closed-loop control, fine-tuning the wire feeding speed or the movement of the forming tool to compensate for the effects of fluctuations in the physical properties of the steel wire, achieving high-precision and high-consistency forming of the spring.

[0041] To further clarify the control logic of this invention, the compensatory adjustment of the central control system 500 is based on a closed-loop feedback control algorithm; this algorithm aims to dynamically compensate for the deviation in forming force caused by fluctuations in the physical properties of the material (such as hardness and diameter) by fine-tuning the kinematic parameters (feeding speed and forming displacement);

[0042] Establish a standard process force model; through trial production of steel wire samples with standard parameters, collect and establish an ideal forming force curve that varies with time, denoted as . The model is stored in the central control system 500 as a benchmark for subsequent production.

[0043] During continuous production, force sensors measure the molding force in real time and obtain the real-time force value. The central control system (500) calculates the force deviation in real time. :

[0044]

[0045] When the absolute value of the deviation When the preset threshold is exceeded, the system initiates a compensatory adjustment; the compensation strategy employs two parallel proportional-integral-derivative (PID) controllers to calculate the adjustment amount for the wire feed speed. and the amount of compensation for displacement of the molded part ;

[0046] Adjustment amount for wire feed speed The calculation formula is:

[0047]

[0048] Compensation amount for displacement of molded parts The calculation formula is:

[0049]

[0050] It is the real-time adjustment amount of the nominal wire feeding speed of the wire feeding mechanism 100;

[0051] It is the real-time compensation amount for the nominal displacement of the forming component (such as the bending pin) in the force feedback forming module 400;

[0052] These are the proportional, integral, and derivative gain coefficients of the speed control loop, respectively. These are the proportional, integral, and derivative gain coefficients of the displacement control loop, respectively.

[0053] It should be noted that these gain coefficients , It is not a dimensionless constant, but a process parameter with specific physical dimensions. Its dimensions ensure the correctness of the relevant PID control formula in a physical sense and the consistency of its dimensions.

[0054] In adjusting the wire feeding speed, the adjustment amount The unit of measurement is length / time (e.g., To ensure dimensional uniformity on both sides of the equation, the dimensions of each gain coefficient in the speed control loop are as follows:

[0055] proportional gain The dimension is (length / time) / force, that is... ;

[0056] Integral gain The dimension of is (length / time) / (force·time), that is ;

[0057] Differential gain The dimensions are (length / time) / (force / time), that is... ;

[0058] In compensating for the displacement of the molded part, the compensation amount The dimension of the quantity is length (e.g., To ensure dimensional uniformity on both sides of the equation, the dimensions of each gain coefficient in the displacement control loop are as follows:

[0059] proportional gain The dimension is length / force, that is... ;

[0060] Integral gain The dimension of this is length / (force·time), that is... ;

[0061] Differential gain Its dimension is length / (force / time), that is... ;

[0062] These gain coefficients need to be pre-tuned and stored in the central control system 500 through experiments or system identification methods based on the specific spring specifications and material properties. Through this dual closed-loop feedback adjustment, it is ensured that even if parameters such as material hardness fluctuate, the forming force can return to the standard process range through dynamic correction of motion parameters, thereby fundamentally guaranteeing the high consistency of the final product's geometric dimensions.

[0063] The pre-straightening and online detection module 200 includes a multi-directional straightening wheel 201, a non-contact sensor 202 for measuring the diameter of the steel wire, and an eddy current sensor 203 for detecting the material of the steel wire; wherein, the non-contact sensor 202 and the eddy current sensor 203 are both electrically connected to the central control system 500.

[0064] In order to achieve accurate online detection of the physical parameters of the steel wire, the pre-straightening and online detection module 200 of this solution serves as the first station for the steel wire to enter the core processing area, and is located between the wire feeding mechanism 100 and the active flexible guide module 300; the module integrates a multi-directional straightening wheel 201, a non-contact sensor 202 and an eddy current sensor 203.

[0065] In practical implementation, when the steel wire passes through the module, it is first physically straightened by the multi-directional straightening wheel group 201 to eliminate the internal stress generated on the material tray and ensure that it enters the subsequent guiding and forming process in a straight posture. Then, the non-contact sensor 202 scans the straight-moving steel wire at high frequency to obtain its real-time and accurate diameter data. At the same time, the eddy current sensor 203 uses the principle of electromagnetic induction to sense the changes in the conductivity or permeability of the steel wire material online, thereby indirectly judging whether its hardness is uniform or whether there are defects such as micro-cracks inside. Both the non-contact sensor 202 and the eddy current sensor 203 are electrically connected to the central control system 500, and transmit the collected diameter and material information as a quantified real-time data stream to the central control system 500, providing key input data for subsequent adaptive control and solving the technical pain point of traditional equipment being unaware of changes in incoming materials.

[0066] The non-contact sensor 202 is a laser biaxial diameter measuring instrument;

[0067] To achieve high-precision, high-frequency non-contact measurement of the wire diameter, the non-contact sensor 202 in this embodiment specifically employs a laser biaxial diameter measuring instrument. This measuring instrument simultaneously emits laser beams from two mutually perpendicular axes (e.g., the X-axis and Y-axis) and receives the light signals after passing through the wire. By calculating the width of the wire's obstruction of the laser beams, its diameter in both axes is determined. Using a laser biaxial diameter measuring instrument enables non-contact measurement, avoiding physical contact between the measuring tool and the wire, thus preventing scratches on the wire surface and avoiding impact on measurement accuracy due to friction and wear. Its high-frequency scanning characteristics ensure that any minute diameter changes during high-speed wire movement can be captured, providing continuous and accurate real-time diameter data for the central control system 500. This forms the basis for precise feedforward control of the downstream active flexible guide module 300.

[0068] The active flexible guide module 300 includes at least two sets of guide units arranged along the direction of the steel wire movement; the guide unit includes at least a pair of guide blocks 302 arranged opposite to each other, the guide blocks 302 together forming a guide hole for constraining the steel wire; the precision actuator 301 is connected to the guide block 302 and is used to drive the guide block 302 to move relative to each other to change the size of the guide hole.

[0069] The core innovative component of this solution, namely the active flexible guide module 300, is located after the pre-alignment and online detection module 200 and before the force feedback forming module 400. In order to achieve stable and dynamically adjustable constraint on the steel wire, the module consists of at least two sets of guide units arranged linearly along the direction of the steel wire's movement. By setting two or more sets of guide units, multi-point constraint can be formed on the steel wire, thereby more effectively suppressing the vibration that may be generated during high-speed movement.

[0070] Each guide unit includes at least one pair of guide blocks 302 that can move relative to each other. The opposing surfaces of the pair of guide blocks 302 are precision machined to form a guide hole through which the steel wire passes. A precision actuator 301 is connected to the back of each guide block 302. These precision actuators 301 receive instructions from the central control system 500 and can drive the guide blocks 302 to translate with micron-level precision, so that the two guide blocks 302 move closer or further apart. This relative movement directly changes the inner diameter of the guide hole. With this structure, the central control system 500 can calculate an optimal guide gap in advance based on the real-time diameter of the steel wire measured by the upstream detection module, and instruct the precision actuators 301 to drive the guide blocks 302 to move, adjusting the guide hole to the matching size before the steel wire arrives.

[0071] The opposite surfaces of the guide block 302 are made of an ultra-wear-resistant, low-friction material;

[0072] To address the problem of rapid wear caused by high-speed friction in traditional guide structures and to further reduce the motion resistance when the steel wire passes through, in this embodiment, the opposing surfaces of the guide block 302 constituting the guide hole are made of a material with ultra-wear-resistant and low coefficient of friction. Specific material selection may include, but is not limited to, hard alloys, engineering ceramics (such as zirconium oxide and silicon nitride), or applying a diamond-like carbon (DLC) coating to the surface of the substrate material.

[0073] The advantages of using this type of material are as follows: First, its extremely high hardness and wear resistance significantly extend the service life of the guide block 302, reducing equipment maintenance costs and downtime caused by component replacement. Second, its extremely low coefficient of friction minimizes the frictional resistance experienced by the wire when passing through the guide hole. This reduces energy consumption in driving the wire feeding mechanism 100 and avoids interference with the wire movement speed caused by friction fluctuations, helping to maintain the stability of the entire system. Furthermore, since the guide clearance can be actively controlled to an optimal light contact or non-contact state, combined with the use of low-friction materials, wear and impact are further reduced, resolving the contradiction between wear resistance and cost.

[0074] The precision actuator 301 is a piezoelectric ceramic actuator or a micro servo motor;

[0075] To achieve rapid and precise driving of the guide block 302 position to match the high-frequency adjustment commands issued by the central control system 500, the precision actuator 301 in this embodiment can specifically be a piezoelectric ceramic actuator or a micro servo motor.

[0076] When a piezoelectric ceramic actuator is selected, its inverse piezoelectric effect can be utilized to apply a control voltage to produce precise displacement on the order of micrometers, with a response speed of milliseconds or even microseconds. This type of actuator has the advantages of small size, high resolution, and fast response speed, and is particularly suitable for applications that require high-speed and minute adjustments to the guide gap.

[0077] When a micro servo motor is selected, the guide block 302 is moved by a transmission mechanism such as a ball screw or precision rack driven by the motor. The micro servo motor can achieve closed-loop position control through its built-in encoder, providing stable and accurate displacement output, and can provide a large driving force.

[0078] Both of these specific implementation methods can meet the requirement that the drive guide block 302 can perform translational movement with micron-level precision, thereby quickly and accurately changing the inner diameter of the guide hole to respond to the control target calculated by the central control system 500 based on real-time wire parameters.

[0079] The forming component 401 includes a bending pin, a pitch gauge, and a cutter;

[0080] To achieve the final forming of the spring steel wire, the forming component 401 included in the force feedback forming module 400 in this embodiment may specifically include a bending pin, a pitch gauge, and a cutter; these components are the direct execution tools for realizing the spring geometry.

[0081] Among them, the bending pin is the core component used to apply force to the steel wire, causing it to undergo plastic deformation and be wound into the required coil diameter; the pitch rule is used to control the spring pitch, that is, the axial distance between adjacent spring coils; the cutter performs a cutting action after the spring is wound to a predetermined number of coils, separating the formed spring from the subsequent steel wire; the movement trajectory, speed, and mutual coordination of these forming components 401 are all precisely controlled by the central control system 500 according to the preset spring process parameters. Step (a): Online detection and data transmission

[0082] The force sensor is a piezoelectric force sensor or a strain gauge force sensor, and is used to connect the molding component 401 to the device frame;

[0083] In order to achieve closed-loop control of force feedback in the molding process, the force sensor in this embodiment can be a high-sensitivity piezoelectric force sensor or a strain gauge force sensor. In terms of structural installation, these molding components 401 (such as bending pins, pitch gauges, and cutters) are not directly and rigidly mounted on the equipment frame, but are mounted on the equipment frame through the force sensor as a connector.

[0084] When the forming component 401 applies a force to the steel wire, the force is transmitted to the force sensor through the forming component 401. The force sensor generates a corresponding electrical signal due to the force (for example, a piezoelectric sensor generates an electric charge, and a strain gauge sensor generates a change in resistance). The sensor converts this force signal into quantified data and feeds it back to the central control system 500.

[0085] The technical advantage of this structure is that it enables real-time monitoring of the forming process. The central control system 500 compares the force values ​​collected in real time with the standard process force value model stored in the database. If the actual forming force deviates from the standard value due to fluctuations in material hardness, the system can immediately make compensatory adjustments, such as fine-tuning the feed speed of the wire feeding mechanism 100 or the displacement compensation of the forming pin, to ensure that even if the material properties fluctuate, the geometric parameters of the final formed spring can still maintain a high degree of consistency, thus solving the problem that the forming quality is sensitive to the steel wire material and that product consistency is difficult to control.

[0086] Compared with existing technologies, this solution achieves significant technological progress and beneficial effects through the collaborative work of its various modules;

[0087] The fundamental flaw of existing technologies lies in their passive processing flow, which cannot sense and adapt to changes in the physical parameters of spring steel wire, leading to sharp contradictions between processing accuracy and production speed, and between the rigidity and flexibility of the guide structure. This solution fundamentally solves these problems by introducing a complete sensing, decision-making, execution and feedback mechanism.

[0088] The beneficial effects of this plan are reflected in the following aspects:

[0089] Firstly, it achieves online quantification and feedforward control of the physical parameters of the steel wire. Existing technologies are unaware of material differences such as steel wire diameter tolerance and material hardness fluctuations. The pre-straightening and online detection module 200 in this solution, through integrated non-contact sensors 202, such as a laser dual-axis diameter measuring instrument, and eddy current sensors 203, transforms the originally unknown physical parameters of the steel wire into a quantifiable real-time data stream, which is then sent to the central control system 500. This design enables the entire device to have predictive capabilities, providing a data foundation for subsequent precise control.

[0090] Secondly, it achieves a balance between guiding accuracy, adaptability, and lifespan. The active flexible guiding module 300 is the core of this solution. It receives instructions from the central control system 500, which are generated based on the actual size of the steel wire detected upstream. The precision actuator 301 inside the module, such as a piezoelectric ceramic actuator or a micro servo motor, drives the guide block 302 to perform rapid micron-level movements, dynamically adjusting the size of the guide hole. This mechanism, which completes the guide gap adjustment before the steel wire arrives, ensures that the steel wire always obtains an optimal channel that provides stable constraints while avoiding excessive friction during high-speed movement. This not only suppresses vibration at the source and ensures subsequent forming accuracy but also integrates the precision of rigid constraints with the adaptability of flexible adjustment. Combined with the guide block 302 made of ultra-wear-resistant, low-friction materials, it significantly reduces component wear and extends the service life of the equipment.

[0091] Thirdly, it achieves closed-loop force feedback control of the forming process. Traditional equipment cannot compensate for fluctuations in forming force caused by changes in material hardness during the forming process. The force feedback forming module 400 in this solution connects forming components 401, such as bending pins and cutters, to the frame through piezoelectric force sensors or strain gauge force sensors. This structure can measure the forming force in real time and feed it back to the central control system 500. When the system finds a deviation between the real-time force value and the standard process force value, it will immediately fine-tune the forming parameters to compensate. This closed-loop control mechanism ensures that even if the mechanical properties of the steel wire fluctuate, each spring produced will still maintain a high degree of consistency in key geometric parameters such as coil diameter and pitch.

[0092] In summary, this solution, through the integrated linkage of the pre-calibration and online detection module 200, the active flexible guidance module 300, the force feedback forming module 400, and the central control system 500, transforms the traditional passive, open-loop processing method of spring machines into an active, adaptive, closed-loop intelligent production method. The technological advancements achieved are systematic, not only improving product precision and consistency but also enhancing the equipment's adaptability and robustness to material changes, while reducing wear on key components, thus possessing significant economic and technical value.

[0093] A method of using an automated spring steel wire forming device with a guiding structure includes the following steps:

[0094] S1. Online detection and data transmission: First, the steel wire is fed into the pre-straightening and online detection module (200) by the wire feeding mechanism (100). This module performs preliminary straightening of the steel wire and detects its physical parameters such as diameter and material through non-contact sensors (202) and eddy current sensors (203). These parameters are then sent to the central control system (500) as real-time data.

[0095] S2. Active guidance control: The central control system (500) performs calculations based on the received real-time wire diameter data and preset process parameters, and sends control commands to the active flexible guidance module (300) to drive the precision actuator (301) inside it. Before the wire arrives, the guide gap between the guide blocks (302) is dynamically adjusted to provide a precisely matched guide channel for the wire.

[0096] S3, Force Feedback Closed-Loop Forming: The precisely guided steel wire enters the force feedback forming module (400). While the forming component (401) performs forming actions such as bending and cutting, the forming force is monitored in real time by the force sensor, and the force data is fed back to the central control system (500).

[0097] S4. Compensatory adjustment: The central control system (500) compares the real-time forming force with the preset standard process force value model. When the force value deviation exceeds the threshold, the closed-loop feedback control algorithm is activated to fine-tune the wire feeding speed of the wire feeding mechanism (100) or the movement of the forming component (401) to compensate for the influence of the fluctuation of the physical properties of the steel wire.

[0098] To better understand the method disclosed in this invention, a specific production scenario will be used as an example for explanation below.

[0099] This embodiment aims to produce a batch of precision springs using standard carbon spring steel wire with a nominal diameter of 1.00 mm. However, in actual production, this batch of steel wire exhibits... Due to the diameter tolerance and slight differences in the drawing process, there is uneven hardness in some areas. The goal of this device is to produce spring products with highly consistent key dimensions such as outer diameter and pitch under high-speed wire feeding conditions of 60 meters per minute.

[0100] Step (a): Online detection and data transmission

[0101] At the start of production, a coil of spring steel wire with a nominal diameter of 1.00 mm is first steadily fed into the device via the wire feeding mechanism (100). The wire then enters the pre-straightening and online detection module (200). Inside the module, a set of multi-directional straightening wheels (201) first applies a precise straightening force to the wire, eliminating the internal stress formed in the coiled state and ensuring that the wire enters the subsequent station in a straight posture.

[0102] Next, the steel wire passes through a laser biaxial diameter measuring instrument. Suppose that at a certain moment, the instrument scans at a frequency of 2000 times per second and detects that the diameter of a 50mm long steel wire is not the ideal 1.00mm, but rather 1.02mm. Simultaneously, the eddy current sensor (203), by detecting changes in the electromagnetic field, finds that the conductivity of this section of wire is slightly lower than that of the standard sample, indicating that its local hardness may be slightly higher than average. These two sensors transmit quantified real-time data—"diameter: 1.02mm" and "material hardness: slightly higher"—to the central control system (500) in milliseconds via a data bus in the form of data packets.

[0103] Step (b): Active guidance control

[0104] Upon receiving data with a diameter of 1.02 mm, the central control system (500) immediately executes the feedforward control algorithm. The system's process database pre-sets the optimal guide clearance to be the actual diameter of the steel wire plus 0.01 mm, in order to minimize friction while providing stable support. Therefore, the system calculates that the target guide hole size should be 1.03 mm.

[0105] The central control system (500) then sends voltage commands to the two sets of four piezoelectric ceramic actuators within the active flexible guide module (300). Within 1-2 milliseconds of receiving the command, the actuators precisely drive the guide block (302) connected to them to translate outward, dynamically adjusting the guide hole made of ultra-wear-resistant hard alloy from 1.01mm, originally set to accommodate a 1.00mm steel wire, to 1.03mm. The entire adjustment process is completed just before the 1.02mm diameter section of steel wire reaches the active flexible guide module (300). Therefore, when this slightly thicker section of steel wire passes through at high speed, it obtains a perfectly matched guide channel, effectively suppressing vibrations that may be caused by size mismatch.

[0106] Step (c): Force feedback closed-loop molding

[0107] After precise guidance, a 1.02mm diameter steel wire segment enters the force feedback forming module (400). A bending pin (one of the forming components 401) in the module begins winding the wire according to a preset program. A standard process force value model within the central control system (500) is used. It is pointed out that for a standard 1.00mm steel wire, at the current winding angle, the forming force that the bending pin should be subjected to is 50.0N.

[0108] However, due to the slightly larger diameter (1.02 mm) and higher hardness of the incoming steel wire, the bending pin encountered greater resistance when bending it. A piezoelectric force sensor installed between the bending pin and the equipment frame detected the actual forming force in real time. The force reached 51.5N. The force sensor immediately fed this high force value back to the central control system (500).

[0109] Step (d): Compensatory Adjustment

[0110] The central control system (500) calculates the force deviation in real time. This deviation exceeded the system's preset limit. The control threshold was reached, immediately triggering the PID closed-loop compensation algorithm.

[0111] The system performs two fine-tuning operations simultaneously:

[0112] Speed ​​adjustment: The PID speed control loop outputs a negative adjustment value. The servo motor of the wire feeding mechanism (100) is instructed to change the wire feeding speed from... Briefly reduced to A slight decrease in speed helps reduce the dynamic resistance during the plastic deformation of the steel wire, thereby reducing the forming force.

[0113] Displacement compensation: The PID displacement control loop outputs a small displacement compensation amount. The servo motor that drives the bending pin adjusts its position by 0.005mm. This tiny displacement slightly increases the forming diameter of the spring, thus significantly reducing the force required for bending.

[0114] Through this series of closed-loop operations—precise to the micrometer and millisecond level—the actual forming force was rapidly corrected back to the target range of 50.0N. Ultimately, despite fluctuations in the physical parameters of the incoming steel wire, the key geometric dimensions of the produced spring (such as coil diameter and pitch) were almost identical to those of springs produced using standard 1.00mm steel wire, thus achieving high precision and high consistency under high-speed production conditions.

[0115] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention in any other way. Any person skilled in the art may make changes or modifications to the above-disclosed technical content to create equivalent embodiments that can be applied to other fields. However, any simple modifications, equivalent changes, and modifications made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the protection scope of the present invention.

Claims

1. An automated spring wire forming apparatus having a guide structure, characterized by, The application relates to an automatic spring wire forming device with a guiding structure, which comprises a wire feeding mechanism (100), a pre-straightening and online detection module (200), an active flexible guiding module (300), a force feedback forming module (400) and a central control system (500). The pre-straightening and online detection module (200), the active flexible guiding module (300) and the force feedback forming module (400) are sequentially connected along the feeding path of the steel wire. The pre-straightening and online detection module (200), the active flexible guiding module (300) and the force feedback forming module (400) are electrically connected with the central control system (500) through a data bus. The pre-straightening and online detection module (200) is used for detecting the physical parameters of the steel wire and sending the parameters to the central control system (500). The active flexible guiding module (300) is internally provided with a precision actuator (301) controlled by the central control system (500), and the precision actuator (301) is used for driving the movement of a guiding block (302) to dynamically adjust the guiding gap provided for the steel wire. The force feedback forming module (400) comprises a forming component (401) and a force sensor connected with the forming component (401), and the force sensor is used for feeding the real-time forming force in the forming process to the central control system (500). The application further relates to a use method of the automatic spring wire forming device with the guiding structure, which comprises the following steps: S1, online detection and data transmission: firstly, the steel wire is sent into the pre-straightening and online detection module (200) by the wire feeding mechanism (100), the module performs preliminary straightening on the steel wire, and the diameter and material physical parameters of the steel wire are detected by a non-contact sensor (202) and an eddy current sensor (203) and are sent to the central control system (500) as real-time data; S2, active guiding control: the central control system (500) performs calculation according to the received real-time steel wire diameter data and preset process parameters, and sends control instructions to the active flexible guiding module (300) to drive the internal precision actuator (301) to dynamically adjust the guiding gap between the guiding blocks (302) before the steel wire arrives, so as to provide an accurate guiding channel for the steel wire; S3, force feedback closed-loop forming: the accurately guided steel wire enters the force feedback forming module (400), the forming component (401) performs bending and cutting forming actions, and the force sensor is used for monitoring the forming force in real time and feeding the force data to the central control system (500); S4, compensatory adjustment: the central control system (500) compares the real-time forming force with a preset standard process force value model, and when the force value deviation exceeds a threshold value, a closed-loop feedback control algorithm is started to finely adjust the wire feeding speed of the wire feeding mechanism (100) or the movement of the forming component (401), so as to compensate the influence of the fluctuation of the physical characteristics of the steel wire. ​ 2. An automated spring wire forming device with a guide structure according to claim 1, characterized in that, The pre-straightening and online detection module (200) comprises a multi-directional straightening wheel (201), a non-contact sensor (202) for measuring the diameter of the steel wire, and an eddy current sensor (203) for detecting the material of the steel wire; wherein the non-contact sensor (202) and the eddy current sensor (203) are electrically connected to the central control system (500).

3. An automated spring wire forming apparatus having a guide structure as defined in claim 2, wherein, The non-contact sensor (202) is a laser double-axis diameter measuring instrument.

4. The automated spring wire forming device with a guide structure according to claim 1, wherein, The active flexible guiding module (300) comprises at least two groups of guiding units arranged along the movement direction of the steel wire; the guiding unit comprises at least one pair of oppositely arranged guiding blocks (302), and the guiding blocks (302) jointly form a guiding hole for constraining the steel wire; the precision actuator (301) is connected with the guiding blocks (302) and is used for driving the relative movement of the guiding blocks (302) to change the size of the guiding hole.

5. An automated spring wire forming apparatus having a guide structure as defined in claim 4, wherein, The opposite surfaces of the guiding blocks (302) are made of super wear-resistant and low-friction materials.

6. An automated spring wire forming apparatus having a guide structure as defined in claim 4, wherein, The precision actuator (301) is a piezoelectric ceramic actuator or a micro servo motor.

7. The automated spring wire forming device with a guide structure according to claim 1, wherein, The forming component (401) comprises a bending pin, a pitch gauge and a cutter.

8. An automated spring wire forming apparatus having a guide structure as defined in claim 7, wherein, The force sensor is a piezoelectric force sensor or a strain force sensor, and is used for connecting the forming component (401) and a device rack.

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