A method for processing a special-shaped torsion spring

Abstract

The present application belongs to the field of process design, and particularly relates to a processing method of a special-shaped torsion spring. The special-shaped torsion spring generally needs to be processed by using a forming tool, and the forming and correction are particularly dependent on the experience and ability of operators, so that the product quality is difficult to guarantee and the processing cycle is long. The processing method of the special-shaped torsion spring utilizes a special tool I and a special tool II, the forming of an open rectangle is completed by the special tool I, the forming of a first torsion part and a second torsion part is completed by the special tool II, the rounding of R7, R8, R9 and R10 is completed by a tool, and the free end is processed into a closed rectangle. Through the processing method, the special-shaped torsion spring is wound, and the time from trial production to completion is reduced from 3 days to 2 hours, so that the production efficiency of the operator and the delivery product quality are significantly improved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of process design, and particularly relates to a processing method of a special-shaped torsion spring. BACKGROUND

[0002] At present, there are various types of springs, and the special-shaped torsion spring generally needs to be processed by using a forming tool. For the special-shaped spring with complex shape, there are more sizes required by the drawing. Since the spring wire has resilience, the position after being wound by the mandrel will be deviated from the size required by the drawing. The forming and correction particularly depend on the experience and ability of the operator, the product quality is difficult to guarantee, and the processing cycle is long.

[0003] Figure 1 And Figure 2 The figure in the present application is a schematic diagram of the special-shaped torsion spring applicable to the present application. In the transverse plane, the lower end has an open rectangle, the open rectangle has rounded corners R1, R2, R3 and R4, the opening has rounded corners R5 and R6, the first torsion part is symmetrically formed by being wound from inside to outside in a positive direction along the opening upward, the diameter is φ1, the upper part of the first torsion part is symmetrically formed by being wound from inside to outside in a reverse direction, the diameter is φ2, there is a rounded corner R10 between the opening and the first torsion part, there are rounded corners R7, R8 and R9 between the first torsion part and the second torsion part, the diameters of the rounded corners R1, R2, R3, R4, R5 and R6 are perpendicular to the transverse plane, the diameters of the first torsion part, the second torsion part, the rounded corners R7, R8, R9 and R10 are parallel to the transverse plane, the distance between the two torsion parts of the first torsion part is d1, and the distance between the two torsion parts of the second torsion part is d2. The upper part of the second torsion part is a free end folded to form a sealed rectangle. SUMMARY

[0004] The present application aims to solve the problems of quality control and low production efficiency of the special-shaped torsion spring, and proposes a processing method of the special-shaped torsion spring.

[0005] The technical scheme of the present application provides a processing method of a special-shaped torsion spring, which has the following structural features: in a transverse plane, the lower end of the special-shaped torsion spring has an open rectangle, the open rectangle has rounded corners R1, R2, R3 and R4, the opening has rounded corners R5 and R6, the first torsion part is symmetrically formed by winding from inside to outside in a positive direction upward along the opening, the diameter of the first torsion part is φ1, the upper part of the first torsion part is a second torsion part symmetrically formed by winding from inside to outside in a reverse direction, the diameter of the second torsion part is φ2, there is a rounded corner R10 between the opening and the first torsion part, there are rounded corners R7, R8 and R9 between the first torsion part and the second torsion part, the diameters of the rounded corners R1, R2, R3, R4, R5 and R6 are perpendicular to the transverse plane, the diameters of the first torsion part, the second torsion part, the rounded corners R7, R8, R9 and R10 are parallel to the transverse plane, the distance between the two torsion parts of the first torsion part is d1, the distance between the two torsion parts of the second torsion part is d2, and the upper part of the second torsion part is a closed rectangle formed by folding the free end, characterized in that the method needs to use a special tool I and a special tool II, wherein

[0006] The special tool I includes a base plate and four forming mandrels and four limiting mandrels mounted on the base plate, the positions of the forming mandrels match the open rectangle of the special-shaped torsion spring, and the limiting mandrels are arranged at the intermediate outer positions of the adjacent forming mandrels;

[0007] The special tool II includes a profile plate, two forming mandrels and one limiting mandrel, the profile plate has an end protrusion, the end protrusion has a positioning groove, the shape and size of the positioning groove are consistent with the design parameters of the open rectangle, the thickness of the profile plate corresponding to the first torsion part is d1, the thickness of the profile plate corresponding to the second torsion part is d2, and the diameters of the two forming mandrels are φ1 and φ2 respectively;

[0008] The method includes the following steps:

[0009] S1, forming the open rectangle by the special tool I;

[0010] S2, forming the first torsion part and the second torsion part by the special tool II;

[0011] S3, forming the rounded corners R7, R8, R9 and R10 by a tool, and processing the free end into a closed rectangle.

[0012] Advantageously, step S1 includes the following sub-steps:

[0013] S1.1, winding the spring steel wire around the forming mandrel to form the rounded corners R1, R2, R3 and R4, and clamping the spring steel wire at the positions of the four rectangular edges inside the limiting mandrel;

[0014] S1.2, respectively pulling out the two free ends of the spring steel wire, and forming the rounded corners R5 and R6 by a tool.

[0015] Advantageously, step S2 comprises the following sub-steps:

[0016] S2.1 fitting the open rectangular sleeve into the positioning groove of the end bump of the special tool II;

[0017] S2.2 rotating and winding the first and second torsion parts in the positive and reverse directions respectively around the forming mandrels on both sides of the profiled plate, and limiting by the limiting mandrels.

[0018] Advantageously, after the end of step S1.1, the following step is needed:

[0019] Advantageously, the forming mandrels on the special tool I comprise a first mandrel, a second mandrel, a third mandrel and a fourth mandrel, the limiting mandrels comprise a fifth mandrel, a sixth mandrel, a seventh mandrel and an eighth mandrel, and the forming mandrels and the limiting mandrels are arranged alternately.

[0020] Advantageously, the forming mandrels on the special tool II comprise a ninth mandrel and an eleventh mandrel, and the limiting mandrel is a tenth mandrel.

[0021] Advantageously, the special tool I and the special tool II need to be clamped on the vice.

[0022] Advantageously, the spring wire is rotated by the winding handle.

[0023] The present application has the following advantages: the special-shaped torsion spring wound by the processing method takes 2 hours from the original 3 days, which significantly improves the production efficiency of the operator and the quality of the delivered product. BRIEF DESCRIPTION OF DRAWINGS

[0024] The exemplary examples and preferred modes of use, other objects, and their descriptions will be best understood by referring to the following detailed description of the examples of the present application, taken in conjunction with the accompanying drawings, which are read in conjunction with the following detailed description of the examples of the present application, wherein:

[0025] Figure 1 is a front view of the special-shaped torsion spring;

[0026] Figure 2 is a right view of the special-shaped torsion spring;

[0027] Figure 3 is a schematic view of the special tool I of the present application;

[0028] Figure 4 is a schematic view of the special tool II of the present application;

[0029] Figure 5 is a partial top view of the special tool II.

[0030] Wherein, 1-first core shaft, 2-second core shaft, 3-third core shaft, 4-fourth core shaft, 5-fifth core shaft, 6-sixth core shaft, 7-seventh core shaft, 8-eighth core shaft, 9-ninth core shaft, 10-tenth core shaft, 11-eleventh core shaft, 12-end bump, 13-positioning groove, 14-profile board DETAILED DESCRIPTION

[0031] The disclosed examples will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, of the disclosed examples are shown. Indeed, a wide variety of examples can be described and many are schematically depicted in the drawings. It should be understood that the drawings are not necessarily to scale and that, in some instances, various aspects of the examples can be shown exaggerated or enlarged to facilitate an understanding of the example as described in the detailed description. In addition, it should be understood that any one or more of the examples can be combined with any one or more of the other examples.

[0032] Embodiment, see Figure 3 The special tool I includes a base plate and first to eighth core shafts 1, 2, 3, 4, 5, 6, 7, and 8 mounted on the base plate, wherein the first four core shafts are forming core shafts matched with the open rectangle of the special-shaped torsion spring, and the last four core shafts are limiting core shafts arranged at the intermediate outer side of adjacent forming core shafts.

[0033] First, the special tool I is clamped on the vice, and if the opening is toward the eighth core shaft 8, the spring wire is clamped outside the first and second core shafts 1 and 2 in the initial state and is limited outside by the sixth core shaft 6. The first end of the spring wire is rotated clockwise around the first core shaft 1 by the twisting hand to form an R1 round corner, and the spring wire is clamped outside the first and third core shafts 1 and 3 and is limited outside by the fifth core shaft 5. The second end of the spring wire is rotated counterclockwise around the second core shaft 2 by the twisting hand to form an R2 round corner and is limited outside by the seventh core shaft 7. At this time, due to the spring-back problem of the spring wire, the operator needs to make a simple correction.

[0034] Then, the first end of the spring wire is rotated clockwise around the third core shaft 3 by the twisting hand to form an R3 round corner, and the second end of the spring wire is rotated counterclockwise around the fourth core shaft 4 by the twisting hand to form an R4 round corner, and the spring wire at both ends is limited by the eighth core shaft 8.

[0035] After that, the two free ends of the spring wire are pulled out respectively, and the round corners R5 and R6 are formed by tools to complete the forming of the open rectangle.

[0036] Embodiment, see Figures 4-5The special tool II includes a profiled plate 14 and end lugs 12 at the ends of the profiled plate 14, the end lugs 12 are provided with positioning grooves 13, the shape and size of the positioning grooves 13 are consistent with the design parameters of the open rectangle, the thickness of the profile of the profiled plate 14 corresponding to the first torsion part is d1, the thickness of the profile of the profiled plate 14 corresponding to the second torsion part is d2, the profiled plate 14 is further provided with a ninth core shaft 9, a tenth core shaft 10 and an eleventh core shaft 11, wherein the ninth core shaft 9 and the eleventh core shaft 11 are forming core shafts, the tenth core shaft 10 is a limiting core shaft, the diameter of the ninth core shaft 9 is φ1, and the diameter of the eleventh core shaft 11 is φ2.

[0037] Then the open rectangle is sleeved on the positioning grooves 13 of the end lugs 12 of the special tool II, the spring wire of the open rectangle is fixed through the positioning grooves 13, then the first torsion part is wound by positively rotating the ninth core shaft 9 on both sides of the profiled plate 14, then the second torsion part is wound by negatively rotating the eleventh core shaft, and is limited by the tenth core shaft 10.

[0038] Finally, the special tool II is removed, and the tool is used to form the fillets R7, R8, R9 and R10, and the free end is processed into a closed rectangle.

[0039] Compared with the previous method of relying only on manual forming by the operator, the production cycle of the torsion spring is shortened, the product variability caused by the skill level of the operator is reduced, and the one-time inspection qualified rate of the product is increased.

[0040] Different examples of the systems, devices, and methods disclosed herein include various components, features, and functionalities. It should be understood that various examples of the systems, devices, and methods disclosed herein can include any of the components, features, and functionalities of any of the other examples of the systems, devices, and methods disclosed herein in any combination or sub-combination, and all such possibilities are intended to fall within the scope of the present disclosure.

[0041] The description of the different advantageous arrangements has been presented for purposes of illustration and description, but is not intended to be exhaustive or limited to the examples disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. Additionally, different advantageous examples can provide different advantages, as compared to other advantageous examples. The chosen examples or examples are selected to best explain the principles of the example, a practical application, and to enable others skilled in the art to best exploit the disclosure.

Claims

1. A method for processing a special-shaped torsion spring, the special-shaped torsion spring having a structure characterized by, in a transverse plane, an open rectangle with rounded corners R1, R2, R3, R4 at a lower end, an opening with rounded corners R5, R6, a first torsion portion symmetrically wound from inside to outside in a positive direction upward from the opening, a diameter of φ1, a second torsion portion symmetrically wound from inside to outside in a reverse direction at an upper portion of the first torsion portion, a diameter of φ2, a rounded corner R10 between the opening and the first torsion portion, rounded corners R7, R8, R9 between the first torsion portion and the second torsion portion, diameters of the rounded corners R1, R2, R3, R4, R5, and R6 being perpendicular to the transverse plane, diameters of the first torsion portion, the second torsion portion, the rounded corners R7, R8, R9, and R10 being parallel to the transverse plane, a distance d1 between two torsion portions of the first torsion portion, a distance d2 between two torsion portions of the second torsion portion, and a closed rectangle formed by folding a free end at an upper portion of the second torsion portion, characterized by: The method needs to use special tool I and special tool II, wherein The special tool I includes a base plate and four forming mandrels and four limiting mandrels mounted on the base plate, the positions of the forming mandrels match the open rectangle of the special-shaped torsion spring, and the limiting mandrels are arranged at the intermediate outer positions of adjacent forming mandrels; The special tool II includes a profiled plate (14) and two forming mandrels and one limiting mandrel, the profiled plate (14) has an end protrusion (12) with a positioning groove (13) on the end protrusion (12), the shape and size of the positioning groove (13) are consistent with the design parameters of the open rectangle, the thickness of the profiled plate (14) corresponding to the first torsion part is d1, and the thickness of the profiled plate (14) corresponding to the second torsion part is d2, the diameters of the two forming mandrels are φ1 and φ2 respectively; The method includes the following steps: S1, forming the open rectangle by the special tool I; S2, forming the first torsion part and the second torsion part by the special tool II; S3, forming the fillets R7, R8, R9 and R10 by a tool, and processing the free end into a closed rectangle.

2. The method of claim 1 wherein: Step S1 includes the following sub-steps: S1.1 winding the spring steel wire around the forming mandrels to form fillets R1, R2, R3 and R4, and clamping the four rectangular edges inside the limiting mandrels; S1.2 respectively pulling out the two free ends of the spring steel wire, and forming fillets R5 and R6 by a tool.

3. The method of claim 2 wherein: Step S2 includes the following sub-steps: S2.1, the open rectangle is sleeved in the positioning groove (13) of the end protrusion (12) of the special tool II; S2.2, winding the spring steel wire around the forming mandrels on both sides of the profiled plate (14) to form the first torsion part and the second torsion part in the forward and reverse directions, and limiting by the limiting mandrel.

4. The method of claim 2 wherein: Step S1.1 also needs to be positive.

5. The method of claim 1 wherein: The forming mandrels on the special tool I include a first mandrel (1), a second mandrel (2), a third mandrel (3) and a fourth mandrel (4), and the limiting mandrels include a fifth mandrel (5), a sixth mandrel (6), a seventh mandrel (7) and an eighth mandrel (8), the forming mandrels and the limiting mandrels are arranged alternately.

6. The method of claim 1 wherein: The forming mandrels on the special tool II include a ninth mandrel (9) and an eleventh mandrel (11), and the limiting mandrel is a tenth mandrel (10).

7. The method of claim 1 wherein: The special tool I and the special tool II need to be clamped on a vice.

8. The method of claim 1 wherein: The spring steel wire is rotated by a twisting hand.

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