Coil Spring Manufacturing via Joule Heating
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Solution Overview
Problem
Conventional methods for manufacturing pocketed coil springs with a heat treatment step are slow due to the need for clamping electrodes and adjusting geometry, which increases production time and reduces efficiency.
Innovation Solution
An apparatus and method that apply an electrical potential difference between tools contacting the wire to heat and deform it into a coil spring, eliminating the need for additional heat-treatment stations and electrode clamping, allowing for precise and controlled heat treatment during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional resistive heating with clamped electrodes is used, then heat treatment can be applied to improve spring resilience and fatigue resistance, but the manufacturing speed decreases significantly
Solution Approach 1:
The patent combines the heat treatment function with the existing coiling tools that already contact the wire during spring formation. The tools serve dual purposes: mechanical deformation and electrical heating, eliminating the need for separate heat treatment stations and electrode clamping operations. This integration maintains manufacturing speed while achieving the desired heat treatment effects for improved spring resilience and fatigue resistance.
Solution Approach 2:
The patent extracts the heat treatment function from the separate electrode clamping and heating process, and integrates it directly into the coiling tools. By removing the need for additional electrode clamping and separate heat treatment stations, the manufacturing process becomes faster while still achieving the necessary thermal treatment for spring reliability.
2Manufacturing precision
If shaped electrodes are clamped to each end of the spring for heat treatment, then proper heat distribution is achieved, but the apparatus complexity and adjustment time increase when changing spring geometries
Solution Approach 1:
The coiling tools are designed to serve multiple functions: they perform both the mechanical coiling operation and the heat treatment function. Since these tools already contact the wire at specific points during spring formation, they can simultaneously apply electrical current for heating without requiring additional specialized electrodes or clamping mechanisms. This universal design eliminates adjustment complexity when changing spring geometries.
Solution Approach 2:
The coiling tools automatically perform both coiling and heat treatment functions during the normal spring formation process. The tools themselves provide the heating function without requiring external electrode clamping or separate adjustment mechanisms. When spring geometry changes, the tools adapt automatically through their existing mechanical adjustments, eliminating the need for manual electrode reconfiguration.
3Reliability
If a separate heat treatment station is added to the manufacturing line, then proper heat treatment can be applied, but the production time increases
Solution Approach 1:
The patent merges the heat treatment function into the existing coiling process by equipping the coiling tools with electrical conductivity and heating capability. This integration allows heat treatment to occur simultaneously with spring formation, eliminating the need for separate heat treatment stations and the associated production time delays. The heat treatment quality is maintained through controlled electrical current application during the coiling operation.
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
This approach speeds up the manufacturing process, enables the production of coil springs with varying geometries without manual adjustments, and achieves improved resilience and resistance to fatigue, comparable to traditional heat treatment methods.
Implementation Method 1
applying an electrical potential difference between the first and second tools, such that an electric current is caused to flow through at least part of the wire
Data Source
AI summary
An apparatus is disclosed for the manufacture of a coil spring from a wire. The apparatus comprises first and second tools for contacting the wire prior to, and/or during, deformation of the wire into a coil spring. The apparatus includes means for applying an electrical potential difference between the first and second tools such that an electric current is caused to flow through at least part of the wire during use.