Angled Spring Treatment Assembly for High-Volume Cooling
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Solution Overview
Problem
Current bagged spring production equipment is limited in processing high volumes of springs within a limited timeframe and factory footprint, lacking efficiency in cooling and tempering springs effectively.
Innovation Solution
An automatic bagged spring production apparatus with a spring treatment assembly featuring two longitudinally oriented subassemblies at an angle, supported by fans for cooling, and a spring welding assembly with double horns made from aluminum, enabling controlled cooling from 130°C to 60°C and efficient processing within a compact space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional single-axis treatment assembly is used, then device complexity is low, but productivity is limited and factory footprint cannot accommodate high volume processing
Solution Approach 1:
The treatment assembly is divided into first and second treatment subassemblies, each with their own longitudinal axes oriented at an angle to each other. This segmentation allows independent processing paths that can handle springs simultaneously, thereby increasing productivity while maintaining manageable complexity through modular design
Solution Approach 2:
By introducing a second treatment subassembly with its longitudinal axis oriented at an angle (e.g., 60°-140°, preferably 90°) relative to the first subassembly's axis, the system transitions from a single-line to a multi-dimensional processing layout. This spatial arrangement enables high-volume processing within a compact factory footprint by utilizing three-dimensional space efficiently
2Productivity
If rapid cooling is applied to springs, then productivity increases, but temperature control precision deteriorates
Solution Approach 1:
Multiple fans are positioned along the spring treatment path to provide continuous cooling action as springs move through the system. This continuous cooling maintains high productivity while the distributed fan arrangement ensures gradual, controlled temperature reduction from 130°C to 60°C, preventing thermal shock and maintaining tempering quality
Solution Approach 2:
The system employs temperature monitoring and control mechanisms that adjust fan operation based on spring temperature conditions. This feedback control enables rapid cooling when needed while maintaining precise temperature management, ensuring springs are properly tempered without compromising productivity
3Use of energy by moving object
If aluminum double horns are used in welding assembly, then power consumption is reduced, but welding strength may be compromised
Solution Approach 1:
The welding system replaces traditional high-power mechanical welding mechanisms with ultrasonic welding technology using aluminum double horns. This substitution reduces power consumption significantly while the ultrasonic vibration mechanism creates strong weld joints through molecular friction and localized heating, maintaining weld strength without high energy input
Solution Approach 2:
The aluminum double horns are designed as specialized components that combine the advantages of aluminum (lightweight, good thermal conductivity, low power consumption) with precise geometric shaping to concentrate ultrasonic energy. This material selection and design create an efficient energy transfer system that achieves strong welding with reduced power requirements
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances cooling efficiency and optimizes working efficiency by allowing high-volume spring processing in a limited space, improving stability and reducing power consumption while overcoming defects in existing equipment.
Implementation Method 1
a plurality of fans positioned adjacent to the first treatment subassembly and a plurality of fans positioned adjacent to the second treatment subassembly oriented to direct cooling air onto springs
Implementation Method 2
automatic bagged spring production apparatus cools and tempers springs in a controlled manner from a temperature of 130° C. to a temperature of 60° C.
Implementation Method 3
the spring welding assembly includes a longitudinal welding tool seat with double horns
Data Source
AI summary
An automatic bagged spring production apparatus comprising a spring treatment assembly including first and second treatment subassemblies, a spring bagging assembly, and a spring welding assembly. The first treatment subassembly includes a first longitudinally axis representing a direction of travel for springs being transported and processed and the second treatment subassembly includes a second longitudinal axis representing a direction of travel for springs being transported and processed, the first longitudinal axis and second longitudinal axis are oriented at an angle relative to each other. The automatic bagged spring production apparatus also includes an apparatus housing in which the spring treatment assembly, the spring bagging assembly and the spring welding assembly are positioned.