Coil Spring Tempering With Direct Electrical Heating
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Solution Overview
Problem
Conventional coil spring manufacturing methods using electric or gas furnaces for tempering result in poor thermal efficiency and non-uniform temperature, leading to variations in quality.
Innovation Solution
A method involving cold forming, quenching in a water-soluble quenching agent, and electrical tempering with controlled electrical heating and gripping members to uniformly heat and temper the shaped material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If tempering is performed in an electric furnace or gas furnace, then the shaped material can be heated and tempered, but the thermal efficiency is poor and temperature distribution is non-uniform
Solution Approach 1:
The patent replaces the conventional furnace-based thermal heating system with an electrical direct heating system. Electrical heating elements are applied directly to the shaped material, eliminating the inefficient thermal radiation and convection mechanisms of furnaces. This substitution achieves both high thermal efficiency (direct energy transfer) and uniform temperature distribution (controlled electrical heating), resolving the technical contradiction between energy loss and manufacturing precision.
Solution Approach 2:
The patent extracts the heating function from the large-scale furnace environment and applies it directly to the shaped material through localized electrical heating. By separating the heating mechanism from the furnace chamber, the system eliminates the thermal inefficiencies and temperature non-uniformity inherent in furnace-based processing, achieving both high energy efficiency and precise temperature control.
2Ease of manufacture
If conventional furnace tempering is used, then the shaping process can be completed, but quality variation occurs due to non-uniform temperature
Solution Approach 1:
The patent replaces the indirect thermal heating of furnaces with direct electrical heating applied to the shaped material. This substitution provides precise control over the heating process, ensuring uniform temperature distribution and eliminating the quality variations caused by furnace temperature non-uniformity, while maintaining the shaping capability.
Solution Approach 2:
The patent implements temperature monitoring and control systems that provide feedback during the electrical heating process. This feedback mechanism ensures that the shaped material reaches and maintains the appropriate tempering temperature uniformly, guaranteeing consistent quality outcomes while preserving the shaping capability.
3Productivity
If electrical heating is applied directly to the shaped material, then thermal efficiency improves and temperature uniformity increases, but new heating methods must be developed
Solution Approach 1:
The patent replaces the complex furnace system with a streamlined electrical heating system that applies heat directly to the shaped material. This substitution simplifies the overall heating infrastructure while dramatically improving tempering speed through direct energy transfer, resolving the contradiction between productivity enhancement and device complexity.
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
Suppresses quality variation, improves shape-forming accuracy, reduces tempering time, and decreases carbon dioxide emissions compared to furnace-based methods.
Implementation Method 1
an electrical tempering step of performing tempering on the shaped material obtained after quenching, by using electrical heating
Implementation Method 2
the shaped material is immersed in a heated water-soluble quenching agent to perform quenching
Data Source
AI summary
A method of manufacturing a coil spring formed by processing a base material made of a wire material includes: performing cold forming on the base material to fabricate a shaped material of spiral shape; performing quenching on the shaped material; and performing tempering on the shaped material obtained after quenching, by using electrical heating.