CNC Wire Bending Head for On- and Off-Plane Loop Forming
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Solution Overview
Problem
Current wire bending technologies are limited in their ability to perform both nose and mandrel bends, and off-plane bending without requiring external robotic arms or clamps, leading to inefficiencies and the need for multiple machines to create complex wire forms.
Innovation Solution
A wire bending apparatus with a center turret cluster, nose-bending mandrel, and mandrel-bending mandrel that can raise, lower, and spin, allowing for both on and off-plane bending capabilities, integrated with a CNC wire bending machine, enabling the formation of complex wire forms without external assistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional nose bending or mandrel bending machines are used, then specific bending operations can be performed, but multiple machines or robot arms are required to perform both nose and mandrel bends and off-plane bending
Solution Approach 1:
The patent combines nose bending and mandrel bending capabilities into a single machine by integrating a nose bending head with a mandrel bending head that can rotate into different positions. This merging eliminates the need for multiple separate machines or robot arms, resolving the contradiction between versatility and device complexity.
Solution Approach 2:
The mandrel bending head is designed to perform multiple functions: it can create loops, perform off-plane bending, and work in conjunction with the nose bending head. This multi-functionality allows a single machine to handle various bending operations that previously required multiple specialized machines.
2Productivity
If mandrel bending is used to form complete loops, then loop formation is achieved in one motion, but the mandrel-bending tool can only create loops of predetermined diameter
Solution Approach 1:
The mandrel bending head is designed to rotate around the wire, dynamically adjusting its position to create loops of varying diameters. This rotational capability transforms a static tool into a dynamic one that can adapt to different loop size requirements while maintaining the efficiency of one-motion loop formation.
Solution Approach 2:
The mandrel bending head operates in three dimensions by rotating around the wire axis, adding a rotational dimension to the bending operation. This enables the creation of loops with variable diameters rather than being constrained to a single predetermined size.
3Adaptability or versatility
If nose bending is used to form loops, then the tool can bend wire to virtually any angle, but the loop is not perfect and requires three or more bends
Solution Approach 1:
The patent merges the nose bending head and mandrel bending head into a single integrated system. The nose bending head provides the initial bend and positioning, while the mandrel bending head completes the loop formation in a more efficient manner, reducing the total number of bends required compared to using nose bending alone.
4Adaptability or versatility
If off-plane bending is performed with conventional machines, then it requires external robot arms or clamps, but this increases device complexity and secondary operations
Solution Approach 1:
The patent integrates off-plane bending capability directly into the wire bending machine by combining the nose bending head with a rotatable mandrel bending head. This eliminates the need for external robot arms or clamps, as the integrated system can perform off-plane bending as a primary operation rather than requiring secondary external equipment.
Data Source
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AI summary
A device and a method are disclosed which relate to a wire bending apparatus capable of both on and off-plane nose and mandrel bends. Exemplary embodiments of the present invention incorporate a center turret cluster (102; 202 etc.) with a plurality of radii possible, a nose-bending mandrel (106; 206 etc.), and a mandrel-bending mandrel (104; 204 etc.). This apparatus forms a bending head that is attached to a CNC wire bending machine. This combination allows increased flexibility in forming complex wire forms and cuts down secondary operations, such as operations from robot arms, sometimes associated with CNC wire bending. In addition, the turret cluster position in the center allows for bending support with mandrel bends or nose bending on the back side of the bending head, usually 180 degrees away from the normal bending area. This allows the manufacturing of double end-loop forms without the addition of external clamps or robotic manipulation.