Simultaneous Coiling of Barrel Spring Opposite Sides
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Solution Overview
Problem
The conventional method for manufacturing barrel coil springs requires multiple processes, including separate coiling of opposite sides, which increases production time and reduces productivity.
Innovation Solution
An apparatus comprising machine frames, transfer units, coilers, and guides that allow simultaneous coiling of opposite sides of the spring material by rotating and adjusting the coilers and guides to coil the spring material around mandrels, reducing the number of manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the spring material is coiled from one end to the other end at one time using a coiler, then the manufacturing process is simplified, but the spring material cannot be removed from the coiler
Solution Approach 1:
The coiling process is divided into two independent simultaneous operations: one coiler coils from one end to the middle, while another coiler coils from the other end to the middle. This segmentation allows both sides to be coiled independently and simultaneously, solving the problem of spring material removal while maintaining process simplicity.
Solution Approach 2:
The invention transitions from sequential one-dimensional coiling to simultaneous two-dimensional coiling by positioning coilers at both ends of the spring material. This dimensional change enables both sides to be coiled at the same time, allowing the spring material to be removed from the middle after both sides are completed.
2Manufacturing precision
If the spring material is coiled twice at the opposite sides using separate processes, then the spring shape is achieved, but the number of working processes is increased and manufacturing time is extended
Solution Approach 1:
The invention merges two separate coiling operations into a single simultaneous process by using multiple coilers working in parallel. Both opposite sides of the spring material are coiled at the same time, reducing the number of working processes from two sequential steps to one simultaneous step, thereby improving productivity while maintaining shape accuracy.
Solution Approach 2:
The coiling process continues simultaneously on both sides of the spring material without interruption or separation. Both coilers operate continuously and concurrently, eliminating the idle time and repositioning required in sequential processes, thus maintaining manufacturing precision while significantly improving productivity.
3Shape
If opposite sides of the spring material are coiled in separate steps, then the coiling direction can be controlled, but the manufacturing time is remarkably increased
Solution Approach 1:
The coiling operation is segmented into independent simultaneous processes at both ends of the spring material. Each coiler maintains its own coiling direction control while operating concurrently with the other, allowing direction control to be preserved without the time penalty of sequential operations.
Solution Approach 2:
Both coilers operate periodically and simultaneously, with each completing its coiling cycle in parallel. This periodic simultaneous action allows both sides to achieve the required coiling direction and shape while reducing total manufacturing time compared to sequential periodic actions.
Data Source
AI summary
An apparatus and method for manufacturing a barrel coil spring make it possible to coil opposite sides of a spring material at the same time so as to considerably reduce manufacturing processing, thereby remarkably reducing the time required to manufacture the coil barrel spring, thus improving productivity.