Coil Spring Forming Guide Mechanism for Pitch Control
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Solution Overview
Problem
Existing coil spring forming apparatuses face challenges in accurately producing coil springs with varying pitches and pitch angles, as they require laborious design and fabrication, lack general applicability, and struggle with controlling the motion of wire material on the core bar, leading to pitch variations and material slippage.
Innovation Solution
A coil spring forming apparatus with independently movable first and second guide members that move in parallel with the core bar to control the pitch and pitch angle of the coil spring, allowing for constant or varying pitches and angles by adjusting their speeds, and featuring guide rollers to ensure smooth wire material feeding regardless of angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a lead screw with spiral groove is used to guide wire material, then the coil spring can be formed with controlled pitch and pitch angle, but the design and fabrication becomes laborious and lacks general applicability
Solution Approach 1:
The guide member is divided into multiple independent guide portions (first guide portion, second guide portion, third guide portion) that can be independently adjusted. Each guide portion controls a specific aspect of the wire material path, allowing flexible configuration without redesigning the entire system for different pitch requirements.
Solution Approach 2:
The guide members are made movable along the axial direction of the core bar, allowing dynamic adjustment of the wire material path during the winding process. This enables continuous variation of pitch and pitch angle without changing the physical structure of the guiding mechanism.
2Device complexity
If a pulley-like guide is used instead of lead screw, then the device complexity is reduced, but the pitch varies and material slippage occurs when pitch changes sharply
Solution Approach 1:
Multiple guide portions act as intermediaries between the wire material and the core bar. These guide portions (first, second, and third guide portions) work together to precisely control the wire material's path, preventing slippage while maintaining simplicity in the overall mechanism.
Solution Approach 2:
The guide members can move independently along the axial direction, allowing dynamic adjustment to maintain consistent pitch control even when pitch changes are required. This movement capability prevents material slippage while keeping the mechanism simple.
3Device complexity
If the guide member is positioned far from the core bar, then the device structure is simplified, but the pitch and pitch angle control becomes inaccurate due to estimation errors
Solution Approach 1:
The guiding function is segmented into multiple portions at different positions. The first guide portion is positioned closer to the core bar to provide accurate reference for pitch control, while other portions handle different aspects of wire guidance, achieving both simplicity and precision.
Solution Approach 2:
The multiple guide portions work in a coordinated manner where the positioning and movement of each guide portion provides feedback information about the wire material path, enabling accurate control of pitch and pitch angle through the combined action of all guide portions.
Data Source
AI summary
A coil spring forming apparatus including a core bar 2 which rotates around an axis thereof and on which a wire material W fed from a wire material-feeding means is wound; a clamping portion 22 which rotates integrally with the core bar 2 and grips an end of the wire material W on the core bar 2; and first guide rollers 30 and second guide rollers 40 for guiding the wire material W onto the core bar 2; wherein the first guide rollers 30 and the second guide rollers 40 are provided so as to move independently from each other in parallel with the axis of the core bar 2, and a coil spring formed by the above coil spring forming apparatus.