Spring wire straightening and feeding device

Abstract

The application belongs to the technical field of spring production equipment, and particularly relates to a spring wire straightening and feeding device, which comprises a rack, a pay-off rack, a wire guide rack, a wire feeding mechanism and a straightening mechanism which are sequentially and oppositely arranged on the top of the rack, and the straightening mechanism comprises a fixing plate, a straightening cylinder, a compression roller, an adjusting assembly, a sensing module and a control unit; the purpose is to actively and timely monitor the actual straightening effect, automatically adjust the key parameters such as the compression holding force and the rotating speed of the compression roller when the straightening effect deviates from the optimal state due to the influence of factors such as the fluctuation of the wire material characteristics and the progressive wear of the compression roller, continuously and dynamically optimize the straightening effect, ensure the consistency of the wire straightening quality in the whole production cycle, minimize the influence of unpredictable factors and component wear on the product quality, significantly reduce the raw material waste and quality control cost, improve the production efficiency and product stability, and meet the use requirements of continuous and high-precision spring production.

Description

Technical Field

[0001] This invention belongs to the technical field of spring production equipment, specifically relating to a spring wire straightening and feeding device. Background Technology

[0002] Springs, as a common mechanical part, are widely used in various mechanical equipment for storing energy, buffering, damping, outputting force, or measuring force. In the process of producing springs, spring machines need to perform processes such as feeding, straightening, and cutting of steel wire. Since the steel wire is initially wound on the wire feeding frame, before spring production, it is necessary to first correct the irregular shape of the steel wire, such as bending and twisting, through the straightening process to make it meet the straightness and perpendicularity requirements of production.

[0003] Currently, while existing spring wire straightening equipment can straighten and adapt wires of different diameters, during long-term continuous operation, the optimal straightening parameters are prone to drift due to changes in working conditions such as slight fluctuations in wire material properties and gradual wear of the roller surface. This leads to a decrease in the consistency of straightening results. Furthermore, existing equipment lacks a real-time monitoring and feedback adjustment mechanism for the straightening effect, failing to proactively detect and compensate for deviations caused by these dynamic factors. Quality problems can only be identified through finished product inspection in the later stages of production, easily resulting in raw material waste and rework, reducing production efficiency and product stability, and failing to meet the demands of continuous, high-precision spring production. Summary of the Invention

[0004] In view of this, the present invention provides a spring wire straightening and feeding device, the purpose of which is to enable the straightening mechanism to dynamically adjust working parameters by introducing intelligent sensing and control technology in order to cope with the influence of factors such as wire characteristics, roller wear and environmental conditions.

[0005] The technical solution adopted in this invention is as follows: A spring wire straightening and feeding device includes a frame. The top of the frame is provided with a wire feeding frame, a wire guide frame, a wire feeding mechanism, and a straightening mechanism arranged sequentially and opposite to each other. The straightening mechanism includes a fixed plate, a straightening cylinder, pressure rollers, an adjusting assembly, a sensing module, and a control unit. The fixed plate is fixedly mounted on the top of the frame and is suitable for assembling the straightening cylinder. The straightening cylinder contains three pressure rollers arranged in an equilateral triangle. The adjusting mechanism drives the roller shaft to move radially to adjust the holding gap. The sensing module includes a torsion sensor located at the outlet of the straightening mechanism. The control unit is electrically connected to both the adjusting mechanism and the sensing module.

[0006] In some embodiments, the adjusting assembly includes: two inner end caps, each sleeved inside both ends of the straightening cylinder, the outer side of which has a ring-shaped array of slots, the number of which is the same as the number of pressure rollers; a lifting block that engages with the slots, the surface of which has a perforation, and both ends of the pressure rollers having connecting rods that pass through the perforations; and a spring located at the bottom of the lifting block, the spring abutting against the bottom inner wall of the slot.

[0007] In some embodiments, the device further includes: a wedge block disposed on the inner side of the lifting block; an outer end cap sleeved on the inner end cap, the inner side of the outer end cap having an inclined inner chamfer adapted to the wedge block; wherein, the inner end cap has an inner sleeve on the side facing the straightening cylinder, the inner sleeve being sleeved inside the straightening cylinder, and the outer end cap has an outer sleeve in the middle, the outer sleeve being movably sleeved on the inner sleeve.

[0008] In some embodiments, a moving mechanism is provided on the outer side of the outer end cover. The moving mechanism includes: a side straight plate, which is distributed opposite to the straightening cylinder and fixed on the frame; a double-ended lead screw, which is disposed between the side straight plates, and its two ends are rotatably connected to the side straight plates through bearings; a moving rod, one end of which is connected to the outer end cover and the other end is threadedly connected to the double-ended lead screw; and a first driving part, which includes a rotating shaft and a first transmission belt, and the rotating shaft is connected to one end of the double-ended lead screw through the first transmission belt.

[0009] In some embodiments, the surface of the inner sleeve is provided with a groove, and the inner wall of the outer sleeve is provided with a protrusion that matches the groove.

[0010] In some embodiments, a gantry frame is provided on the top of the fixed plate, the straightening cylinder is located inside the gantry frame, and a second drive unit is provided on the top of the gantry frame. The top of the straightening cylinder is provided with a slot, and a second transmission belt is sleeved on the output shaft of the second drive unit. The second transmission belt passes through the slot and is connected to one of the pressure rollers inside the straightening cylinder.

[0011] In some embodiments, the wire feeding frame includes two opposing upright plates, which are fixed to the top of the frame. A wire feeding roller is rotatably connected between the two upright plates. Both ends of the wire feeding roller are provided with limiting discs, and the diameter of the limiting discs is larger than the diameter of the wire feeding roller.

[0012] In some embodiments, the wire feeding mechanism includes a third drive unit, a first roller, a support base, and a second roller. The support base is fixed to the top of the frame. The first roller and the second roller are disposed opposite each other on the top of the support base. The third drive unit is fixed to one side of the support base, and its output shaft is connected to the roller shaft of the first roller through a gear set. The surfaces of the first roller and the second roller are both provided with annular grooves adapted to the wire, and the two cooperate to form a wire feeding channel.

[0013] In some embodiments, the sensing module further includes a proximity sensor and a tension sensor. The proximity sensor is disposed on the inner wall of the straightening cylinder and is adapted to detect radial movement of the pressure roller. The tension sensor is disposed between the wire feeding mechanism and the straightening cylinder and is adapted to detect wire tension.

[0014] In some embodiments, the control unit incorporates a PID control algorithm, which is suitable for automatically adjusting the gap and speed of the pressure rollers based on the straightness deviation of the wire, and for providing early warning of pressure roller wear.

[0015] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are: 1. This invention integrates multi-dimensional sensing modules and adaptive control units to construct a closed-loop feedback control system. This system can actively monitor the actual straightening effect in real time. When the straightening effect deviates from the optimal state due to factors such as fluctuations in wire material characteristics and progressive wear of pressure rollers, it can automatically adjust key parameters such as pressure roller holding force and rotation speed. Through continuous dynamic optimization, it ensures the consistency of wire straightening quality throughout the entire production cycle, minimizes the impact of unpredictable factors and component wear on product quality, significantly reduces raw material waste and quality control costs, improves production efficiency and product stability, and meets the needs of continuous, high-precision spring production.

[0016] 2. This invention, by setting three pressure rollers arranged in an equilateral triangle, provides stable clamping and straightening of the wire from three directions. Compared to traditional asymmetrical arrangements of two or more rollers, the equilateral triangle arrangement of the pressure rollers ensures more uniform radial pressure on the wire during straightening, effectively preventing lateral bending or localized stress concentration caused by uneven force.

[0017] 3. In this invention, each pressure roller can be independently adjusted radially. The clamping gap between the pressure roller and the wire is controlled by the adjustment component, thereby adapting to the straightening requirements of spring wires of different diameters. When the wire passes through the straightening cylinder, the three pressure rollers work together to correct the original irregular shape of the wire, such as bending and twisting, in a multi-directional and gradual manner, ensuring that the wire obtains stable and consistent straightness during axial conveying, and providing high-quality wire blanks for subsequent spring forming processes. Attached Figure Description

[0018] The present invention will be described by way of example and with reference to the accompanying drawings, wherein: Figure 1 This is a schematic diagram of the spring wire straightening and feeding device provided by the present invention.

[0019] Figure 2 This is a schematic diagram of the moving mechanism provided by the present invention.

[0020] Figure 3 This is a schematic diagram of the straightening cylinder provided by the present invention.

[0021] Figure 4 This is a schematic diagram of the connection between the inner end cap and the outer end cap provided by the present invention.

[0022] Figure 5 This is a schematic diagram of the structure of the inner end cap provided by the present invention.

[0023] Figure 6 This is a cross-sectional schematic diagram of the outer sleeve and inner sleeve provided by the present invention.

[0024] Figure 7 This is a schematic diagram of the lifting block provided by the present invention.

[0025] Figure 8 This is a schematic diagram showing the distribution of the second drive unit and the pressure roller provided by the present invention.

[0026] Figure 9 This is a cross-sectional schematic diagram of the straightening cylinder provided by the present invention.

[0027] Figure 10 This is a schematic diagram of the wire feeding mechanism provided by the present invention.

[0028] 1. Frame; 2. Pay-off frame; 3. Pay-off roller; 4. Wire guide frame; 5. Wire feeding mechanism; 6. Fixing plate; 7. Straightening cylinder; 8. Twist sensor; 9. Side straight plate; 10. Moving rod; 11. Double-ended lead screw; 12. First drive unit; 13. Rotating shaft; 14. First transmission belt; 15. Gantry frame; 16. Second drive unit; 17. Outer end cover; 18. Outer sleeve; 19. Inner end cover; 20. Inner sleeve; 21. Lifting block; 22. Wedge block; 23. Protrusion; 24. Groove; 25. Slot; 26. Perforation; 27. Spring; 28. Pressure roller; 29. ​​Connecting rod; 30. Second transmission belt; 31. Proximity sensor; 32. Third drive unit; 33. First roller; 34. Support base; 35. Second roller; 36. Tension sensor. Detailed Implementation

[0029] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0030] In existing technologies, while spring machine wire straightening equipment can adapt to the straightening needs of wires with different diameters, the optimal straightening parameters are prone to drift during long-term continuous operation due to changes in working conditions such as slight fluctuations in wire material properties and gradual wear of the roller surface. This leads to a decrease in the consistency of straightening results. Furthermore, existing equipment lacks a real-time monitoring and feedback adjustment mechanism for the straightening effect, failing to proactively detect and compensate for deviations caused by these dynamic factors. Quality problems can only be identified through finished product inspection in the later stages of production, easily resulting in raw material waste and rework, reducing production efficiency and product stability, and making it difficult to meet the requirements of continuous, high-precision spring production.

[0031] Therefore, in order to solve the above problems and achieve the goal of being able to cope with the influence of factors such as steel wire characteristics, roller wear, and environmental conditions, this invention discloses a spring wire straightening and feeding device, see reference. Figures 1-8 The system includes a frame 1, on the top of which are arranged in sequence and opposite to each other: a wire feeding frame 2, a wire guide frame 4, a wire feeding mechanism 5, and a straightening mechanism. The straightening mechanism includes a fixing plate 6, a straightening cylinder 7, pressure rollers 28, an adjustment component, a sensing module, and a control unit. The fixing plate 6 is fixedly disposed on the top of the frame 1 and is adapted to assemble the straightening cylinder 7. The straightening cylinder 7 has three pressure rollers 28 arranged in an equilateral triangle. The adjustment component is used to drive the roller shaft to move radially to adjust the holding gap. The sensing module includes a torsion sensor 8 located at the outlet of the straightening mechanism. The control unit is electrically connected to the adjustment component and the sensing module.

[0032] In this embodiment, the frame 1 is welded from high-strength steel and has anti-slip pads at the bottom to ensure stability during long-term continuous operation and prevent vibration from affecting the straightening accuracy. The wire feeding frame 2, wire guide frame 4, wire feeding mechanism 5, and straightening mechanism are arranged sequentially along the length of the frame 1, with the center lines of each component kept on the same horizontal line to ensure that the spring wire can be smoothly transported and continuously straightened, reducing jamming and offset problems during the transport process.

[0033] The wire feeding frame 2 includes two opposing upright plates, which are fixed to the top of the frame 1 by expansion bolts. A wire feeding roller 3 is rotatably connected between the two upright plates by bearings. The wire feeding roller 3 is used to wind the spring wire to be straightened. Both ends of the roller 3 are integrally formed with limit discs. The diameter of the limit discs is larger than the diameter of the wire feeding roller 3, which can axially limit the wire wound on the wire feeding roller 3 to prevent the wire from shifting or falling off during the wire feeding process, ensuring that the wire feeding process is stable and orderly, and providing a stable supply of wire for subsequent wire feeding and straightening processes.

[0034] Furthermore, the wire guide 4 is located between the wire feeding frame 2 and the wire delivery mechanism 5, and consists of two symmetrically arranged wire guide wheels. The wire guide wheels are fixed to the top of the frame 1 by a bracket. The two wire guide wheels are distributed opposite each other, and the surface is provided with an arc-shaped groove adapted to the wire. The two work together to form a wire channel, which can guide and straighten the wire released by the wire feeding roller 3, avoid the wire from bending or deviating during the conveying process, ensure that the wire can accurately enter the wire delivery mechanism 5, and reduce the wire delivery resistance.

[0035] Furthermore, the wire feeding mechanism 5 includes a third drive unit 32, a first roller 33, a support base 34, and a second roller 35. The support base 34 is fixed to the top of the frame 1 by bolts. The first roller 33 and the second roller 35 are disposed opposite each other on the top of the support base 34, with their axes parallel. The first roller 33 is located below, and the second roller 35 is located above and can be adjusted up and down slightly. The third drive unit 32 is a servo motor, fixed to one side of the support base 34. Its output shaft is connected to the roller shaft of the first roller 33 through a gear set, which can drive the first roller 33 to rotate at a constant speed. The surfaces of the first roller 33 and the second roller 35 are both provided with annular grooves adapted to the wire. The curvature of the annular groove matches the diameter of the wire. The two work together to form a wire feeding channel. When the first roller 33 rotates, it drives the wire forward through friction. At the same time, the second roller 35 presses the wire to ensure that the wire feeding process is stable and to prevent the wire from slipping. The distance between the first roller 33 and the second roller 35 can be flexibly adjusted according to the diameter of the wire to adapt to the wire feeding requirements of different specifications of spring wire.

[0036] The straightening mechanism includes a fixed plate 6 that is fixed to the top of the frame 1 by bolts. A gantry frame 15 is provided on the top of the fixed plate 6. The straightening cylinder 7 is placed horizontally inside the gantry frame 15 and is fixedly connected to the fixed plate 6 by bolts to ensure that the straightening cylinder 7 is installed firmly and to avoid shaking during the straightening process.

[0037] Preferably, the straightening cylinder 7 has three pressure rollers 28 inside, which are arranged in an equilateral triangle. The central area formed is the straightening channel. When the wire passes through the straightening channel, the three pressure rollers 28 press and straighten the wire from different directions, which can simultaneously eliminate the bending and twisting deformation of the wire and improve the straightening accuracy. Compared with the traditional double roller straightening, the pressure rollers 28 arranged in an equilateral triangle can make the wire more uniformly stressed and the straightening effect more stable.

[0038] It should be noted that a shearing mechanism is also provided between the straightening cylinder 7 and the wire feeding mechanism 5. The shearing mechanism is used to cut the steel wire before it enters the straightening cylinder 7. After the cut steel wire enters the straightening cylinder 7, it will be rotated along with the three pressure rollers 28 while receiving the rotational pressure of the three pressure rollers 28. This rotation, combined with the holding force of the pressure rollers 28, can straighten the steel wire in all directions.

[0039] Furthermore, the adjustment assembly is used to drive the pressure rollers 28 to move radially, thereby adjusting the holding gap between the three pressure rollers 28 to adapt to wires of different diameters and different straightening requirements. Specifically, it includes an inner end cap 19, a lifting block 21, a spring 27, a wedge block 22, and an outer end cap 17. Two inner end caps 19 are provided, respectively fitted inside both ends of the straightening cylinder 7. The inner end caps 19 are tightly fitted to the inner wall of the straightening cylinder 7. The outer side of the inner end caps 19 is provided with a ring-shaped array of slots 25. The number of slots 25 is the same as the number of pressure rollers 28, both being three. The three slots 25 are distributed in an equilateral triangle, corresponding one-to-one with the positions of the three pressure rollers 28. The lifting block 21 is fitted into the slot 25 and can move up and down along the slot 25. The surface of the lifting block 21 is provided with a through hole 26. Both ends of the pressure roller 28 are integrally formed with a connecting rod 29. The connecting rod 29 passes through the through hole 26, so that the pressure roller 28 can rotate around the connecting rod 29, ensuring that the pressure roller 28 can rotate synchronously when the wire is conveyed, and reducing the friction loss between the wire and the pressure roller 28.

[0040] In the above structure, the spring 27 is located at the bottom of the lifting block 21. One end of the spring 27 is fixedly connected to the bottom of the lifting block 21, and the other end abuts against the bottom inner wall of the slot 25. The spring 27 is always in a compressed state and can apply an upward elastic force to the lifting block 21, so that the lifting block 21 always has an upward tendency, thereby driving the pressure roller 28 away from the center of the straightening channel. The wedge block 22 is fixedly installed on the inner side of the lifting block 21 and is inclined. The outer end cover 17 is sleeved on the inner end cover 19. The inner side of the outer end cover 17 is provided with an inclined inner chamfer that matches the wedge block 22. When the outer end cover 17 moves away from the straightening cylinder 7, the inclined inner chamfer abuts against the wedge block 22, pushing the wedge block 22 to sink. At this time, the spring 27 contracts, thereby driving the lifting block 21 to move downward along the slot 25, and then driving the pressure roller 28 to move closer to the center of the straightening channel, reducing the holding gap. Conversely, when the outer end cover 17 moves towards the straightening cylinder 7, the elastic force of the spring 27 pushes the lifting block 21 to move upward, driving the pressure roller 28 away from the center of the straightening channel, increasing the holding gap.

[0041] The inner end cap 19 has an integrally formed inner sleeve 20 on the side facing the straightening cylinder 7. The inner sleeve 20 is inserted into the straightening cylinder 7 and is connected to the straightening channel inside the straightening cylinder 7. The cut steel wire can enter and exit the straightening channel through the inner sleeve 20. The outer end cap 17 has an integrally formed outer sleeve 18 in the middle. The outer sleeve 18 is movably sleeved on the inner sleeve 20. The surface of the inner sleeve 20 has a groove 24. The inner wall of the outer sleeve 18 has a protrusion 23 that matches the groove 24. The protrusion 23 is fitted into the groove 24, which can restrict the rotation of the outer end cap 17 and ensure that the outer end cap 17 can accurately push the wedge block 22 when it moves, avoiding deviation, and at the same time enhancing the connection stability between the outer end cap 17 and the inner end cap 19.

[0042] To facilitate the smooth movement of the outer end cap 17, a moving mechanism is provided on the outer side of the outer end cap 17. This mechanism drives the outer end cap 17 to move axially along the inner sleeve 20, thereby adjusting the pressing gap. The moving mechanism includes a side straight plate 9, a double-ended lead screw 11, a moving rod 10, and a first driving part 12. Two side straight plates 9 may be provided, distributed opposite to the straightening cylinder 7 and fixed to the frame 1 with bolts. The two side straight plates 9 are symmetrically arranged on both sides of the straightening cylinder 7. Both side straight plates 9 are equipped with double-ended lead screws 11. The two ends of the double-ended lead screws 11 are rotatably connected to the side straight plates 9 through bearings and can rotate around their own axes. There are two sets of moving rods 10, which correspond to the two outer end caps 17 respectively. One end of the moving rod 10 is connected to the outer end cap 17 through a hinge, and the other end is threaded to the double-ended lead screw 11. The two ends of the double-ended lead screw 11 have opposite threads. When the double-ended lead screw 11 rotates, the two moving rods 10 can drive the two outer end caps 17 to move synchronously towards or away from the straightening cylinder 7, so as to ensure that the gap adjustment of the pressure rollers 28 at both ends of the straightening cylinder 7 is consistent and to avoid straightening deviation caused by uneven gap at both ends.

[0043] The first drive unit 12 can be a servo motor, with the rotating shaft 13 as its output shaft. One end of the servo motor is connected to one end of the double-ended lead screw 11 via the first transmission belt 14. After the servo motor is started, it drives the double-ended lead screw 11 to rotate via the rotating shaft 13 and the first transmission belt 14, thereby driving the outer end cover 17 to move, realizing the automatic adjustment of the holding gap. The adjustment accuracy is high, which can adapt to the straightening requirements of different specifications of wires, while reducing the workload of manual adjustment and improving production efficiency.

[0044] The top of the gantry frame 15 is provided with a second drive unit 16, which can be a servo motor. The top of the straightening cylinder 7 is provided with a slot. A second transmission belt 30 is sleeved on the output shaft of the second drive unit 16. The second transmission belt 30 passes through the slot and is connected to the connecting rod 29 of one of the pressure rollers 28 inside the straightening cylinder 7. After the second drive unit 16 is started, it drives the pressure roller 28 to rotate through the second transmission belt 30. Since the wire is in contact with all three pressure rollers 28, the rotating pressure roller 28 can drive the wire forward through friction, while assisting in straightening, ensuring smooth wire feeding, and further improving the straightening effect. The rotation speed of the pressure roller 28 can be adjusted by the second drive unit 16 to adapt to different wire feeding speed requirements.

[0045] Furthermore, the sensing module provides multi-dimensional real-time data support for the adaptive adjustment of the control unit, specifically including: a torsion sensor 8, a proximity sensor 31, and a tension sensor 36.

[0046] The torsion sensor 8 is a non-contact laser sensor (either a line laser scanner or a multi-point laser array) located at the outlet of the straightening mechanism and fixed to the frame 1 by a bracket. Its detection end is aligned with the straightened wire and can capture the residual bending or torsion of the wire in real time, capturing minute deformations that are difficult to detect with the naked eye, as the core indicator for measuring the straightening effect.

[0047] The proximity sensor 31 is located on the inner wall of the straightening cylinder 7, corresponding to the position of the pressure roller 28, and monitors the radial position of each pressure roller 28 in real time. By analyzing the deviation between the actual position of the pressure roller 28 and the set value, and combining it with historical monitoring data, the wear degree of the pressure roller 28 can be indirectly assessed.

[0048] The tension sensor 36 can be a weighing tension sensor 36, which is located between the wire feeding mechanism 5 and the straightening cylinder 7. The wire passes through its detection end, and the tension of the wire entering the cylinder is measured in real time to avoid tension fluctuations affecting the straightening effect.

[0049] Referring to the above implementation method, the control unit adopts an industrial-grade PLC or embedded controller, fixed on one side of the frame 1, with a built-in PID control algorithm, and is electrically connected to the adjustment component, sensing module, first drive unit 12, second drive unit 16, and third drive unit 32 respectively, forming a closed-loop feedback control system to realize adaptive dynamic adjustment of the calibration parameters. The specific control logic is as follows: First, the control unit continuously collects multi-dimensional data transmitted by all sensing modules, performs data fusion and performance evaluation. Among them, the straightness and twist data of the wire detected by the twist sensor 8 serve as the core performance feedback. The system presets a clear target straightness and twist tolerance range as the evaluation standard for the straightening effect.

[0050] Secondly, the dynamic parameter adjustment algorithm is divided into two stages: initial intelligent calibration and real-time adaptive compensation. In the initial intelligent calibration stage, when changing the wire reel or adjusting the wire diameter, there is no need to rely on manual experience to set parameters. The system automatically performs intelligent calibration, precisely controlling the holding force of the pressure roller 28 through the servo motor of the first drive unit 12, adjusting the speed of the second drive unit 16, and simultaneously monitoring the data of the torsion sensor 8 in real time. It automatically searches and determines the optimal combination of holding force and speed of the pressure roller 28 corresponding to the current wire batch and diameter, thus completing the initial calibration. In the real-time adaptive compensation stage, during continuous production, if the torsion sensor 8 detects that the wire straightening effect deviates from the target tolerance, such as residual curvature or torsion exceeding the preset threshold, the adaptive control algorithm immediately activates the compensation mechanism. It first refers to the data of the tension sensor 36 to determine whether there is external interference, and then, based on the magnitude and trend of the deviation, makes small-amplitude, incremental fine adjustments to the holding force of the pressure roller 28 through the servo motor of the first drive unit 12, while simultaneously adjusting the speed of the second drive unit 16. The PID control algorithm brings the straightening effect back to the optimal state.

[0051] Finally, the control unit also has intelligent wear warning and abnormal detection alarm functions. During long-term operation, if the system needs to continuously increase the holding force of the pressure roller 28 to achieve the target straightening effect, it can be inferred that the pressure roller 28 is gradually worn. The control unit records the wear trend and issues a warning to the operator in a timely manner, prompting them to check or replace the pressure roller 28, thus achieving preventive maintenance. If the straightening effect still cannot be restored to the target range after multiple parameter adjustments, or if the sensor data indicates a mechanical fault, such as the pressure roller 28 position sensor not responding, the system will immediately trigger an alarm and can selectively suspend production to prevent unqualified wire from entering subsequent processes and avoid waste of raw materials.

[0052] In this embodiment, the spring wire straightening and feeding device first winds the spring wire to be straightened onto the feed roller 3. One end of the wire passes sequentially through the wire channel of the wire frame 4, the wire feeding channel of the feeding mechanism 5, and the straightening channel of the straightening mechanism to complete the wire threading. Then, the control unit is activated and the straightening parameters are preset, such as the holding gap, the feeding speed, the rotation speed of the pressure roller 28, the torsion threshold, and the tension threshold. The control unit controls the third drive unit 32 to start, driving the first roller 33 to rotate and driving the wire forward at a uniform speed. At the same time, the control unit controls the second drive unit 16 to start, driving the pressure roller 28 in the straightening cylinder 7 to rotate, assisting in the wire feeding and straightening. The adjustment component, according to the preset holding gap, drives the outer end cover 17 to move through the moving mechanism to adjust the gap between the three pressure rollers 28, so that the pressure rollers 28 can stably hold the wire.

[0053] During the straightening process, the sensing module continuously collects multi-dimensional data and transmits it to the control unit: the torsion sensor 8 detects the residual bending and torsion of the wire, the proximity sensor 31 monitors the radial position of the pressure roller 28, the tension sensor 36 collects the wire feeding tension, and the temperature sensor provides feedback on the working temperature of the pressure roller 28 and the ambient temperature. The control unit integrates and analyzes all the data, and, combined with the preset target tolerance range, executes adaptive adjustment logic: if the wire straightening effect is detected to deviate from the threshold, it first judges external interference factors such as tension, and then fine-tunes the holding force and speed of the pressure roller 28 through the PID algorithm to achieve real-time compensation; if progressive wear of the pressure roller 28 is detected, a warning signal is issued in a timely manner; if a mechanical failure occurs or the straightening effect cannot be recovered, an alarm is immediately triggered and production is selectively suspended. The straightened wire is discharged from the straightening mechanism outlet and enters the subsequent spring 27 production process, realizing continuous and precise straightening and feeding of the wire.

[0054] The above embodiments, by integrating multi-dimensional sensing modules and adaptive control units, construct a closed-loop feedback control system, effectively solving the technical problem that existing equipment struggles to cope with adverse effects such as wire characteristics and roller wear. This system no longer relies on initial calibration and passive elastic support, but actively and in real-time monitors the actual straightening effect. When the straightening effect deviates from the optimal state due to factors such as fluctuations in wire material characteristics and progressive wear of the pressure roller 28, it can automatically adjust key parameters such as the pressure force and rotation speed of the pressure roller 28. Through continuous dynamic optimization, it ensures the consistency of wire straightening quality throughout the entire production cycle, minimizing the impact of unpredictable factors and component wear on product quality, significantly reducing raw material waste and quality control costs, improving production efficiency and product stability, and meeting the needs of continuous, high-precision spring 27 production.

[0055] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0056] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A spring wire straightening and feeding device, comprising a frame (1), wherein the top of the frame (1) is provided with a wire feeding frame (2), a wire guide frame (4), a wire feeding mechanism (5), and a straightening mechanism arranged sequentially opposite to each other, characterized in that, The straightening mechanism includes a fixed plate (6), a straightening cylinder (7), a pressure roller (28), an adjustment component, a sensing module, and a control unit. The fixed plate (6) is fixedly installed on the top of the frame (1) and is suitable for assembling the straightening cylinder (7). The straightening cylinder (7) is provided with a pressure roller (28) inside. There are three pressure rollers (28), which are arranged in an equilateral triangle. The adjustment mechanism is used to drive the roller shaft to move radially to adjust the holding gap. The sensing module includes a torsion sensor (8) located at the outlet of the straightening mechanism. The control unit is electrically connected to the adjustment mechanism and the sensing module respectively.

2. The spring wire straightening and feeding device according to claim 1, characterized in that, The adjustment assembly includes: an inner end cap (19), two inner end caps (19) are provided, and the two inner end caps (19) are respectively fitted inside the two ends of the straightening cylinder (7). The outer side of the inner end cap (19) is provided with a ring-shaped array of slots (25), and the number of slots (25) is the same as the number of pressure rollers (28); a lifting block (21), the lifting block (21) is fitted into the slots (25), and the surface of the lifting block (21) is provided with a perforation (26). Both ends of the pressure roller (28) are provided with connecting rods (29), and the connecting rods (29) are inserted into the perforations (26); and a spring (27), the spring (27) is provided at the bottom of the lifting block (21), and the spring (27) abuts against the bottom inner wall of the slot (25).

3. The spring wire straightening and feeding device according to claim 2, characterized in that, Also includes: Wedge block (22), the wedge block (22) is located on the inner side of the lifting block (21); outer end cover (17), the outer end cover (17) is sleeved on the inner end cover (19), the inner side of the outer end cover (17) is provided with an inclined inner chamfer that matches the wedge block (22); wherein, the inner end cover (19) is provided with an inner sleeve (20) on the side facing the straightening cylinder (7), the inner sleeve (20) passes through the straightening cylinder (7), and the outer end cover (17) is provided with an outer sleeve (18) in the middle, the outer sleeve (18) is movably sleeved on the inner sleeve (20).

4. The spring wire straightening and feeding device according to claim 3, characterized in that, The outer end cover (17) is provided with a moving mechanism, which includes: a side straight plate (9), which is distributed opposite to the straightening cylinder (7) and fixed on the frame (1); a double-ended lead screw (11), which is located between the side straight plates (9), and the two ends of the double-ended lead screw (11) are rotatably connected to the side straight plate (9) through bearings; a moving rod (10), one end of the moving rod (10) is connected to the outer end cover (17), and the other end is threadedly connected to the double-ended lead screw (11); a first driving part (12), which includes a rotating shaft (13) and a first transmission belt (14), and the rotating shaft (13) is connected to one end of the double-ended lead screw (11) through the first transmission belt (14).

5. The spring wire straightening and feeding device according to claim 3, characterized in that, The inner sleeve (20) has a groove (24) on its surface, and the inner wall of the outer sleeve (18) has a protrusion (23) that matches the groove (24).

6. The spring wire straightening and feeding device according to claim 1, characterized in that, The top of the fixed plate (6) is provided with a gantry frame (15), the straightening cylinder (7) is located inside the gantry frame (15), the top of the gantry frame (15) is provided with a second drive unit (16), wherein the top of the straightening cylinder (7) is provided with a slot, and a second transmission belt (30) is sleeved on the output shaft of the second drive unit (16), the second transmission belt (30) passes through the slot and is connected to one of the pressure rollers (28) inside the straightening cylinder (7).

7. The spring wire straightening and feeding device according to claim 1, characterized in that, The wire feeding frame (2) includes two opposing upright plates, which are fixed to the top of the frame (1). A wire feeding roller (3) is rotatably connected between the two upright plates. Both ends of the wire feeding roller (3) are provided with limiting plates, and the diameter of the limiting plates is larger than the diameter of the wire feeding roller (3).

8. The spring wire straightening and feeding device according to claim 1, characterized in that, The wire feeding mechanism (5) includes a third drive unit (32), a first roller (33), a support base (34), and a second roller (35). The support base (34) is fixed to the top of the frame (1). The first roller (33) and the second roller (35) are disposed opposite each other on the top of the support base (34). The third drive unit (32) is fixed to one side of the support base (34). Its output shaft is connected to the roller shaft of the first roller (33) through a gear set. The surfaces of the first roller (33) and the second roller (35) are both provided with annular grooves adapted to the wire, and the two cooperate to form a wire feeding channel.

9. The spring wire straightening and feeding device according to claim 1, characterized in that, The sensing module also includes a proximity sensor (31) and a tension sensor (36). The proximity sensor (31) is located on the inner wall of the straightening cylinder (7) and is adapted to detect the radial movement of the pressure roller (28). The tension sensor (36) is located between the wire feeding mechanism (5) and the straightening cylinder (7) and is adapted to detect the tension of the wire.

10. The spring wire straightening and feeding device according to claim 1, characterized in that, The control unit has a built-in PID control algorithm, which is suitable for automatically adjusting the gap and speed of the pressure roller (28) according to the straightness deviation of the wire, and realizing the wear warning of the pressure roller (28).

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