Coil Spring Coating Positioning Using Laser Profile Feedback
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Solution Overview
Problem
Existing methods for applying coating materials to coil springs result in inaccurate positioning due to deviations when coil spring tolerances are large, leading to suboptimal application.
Innovation Solution
A coating material application system with a support base, sensor, and movement devices controlled by a device that measures coil spring positions, calculates application points, and applies coating material with high accuracy by shifting measurement and application positions by specific angles, using laser light to profile the coil spring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the powder coating gun is moved in synchronization with the rotation of the coil spring based on desired design shape, then the application process is simple, but the position of application deviates from desired position when tolerance is large
Solution Approach 1:
The system performs preliminary measurement of the actual coil spring position before coating application. The measurement unit measures the actual position of the coil spring in the radial direction, and this measurement data is used to calculate corrected application positions, ensuring accurate coating even when the coil spring has large tolerances
Solution Approach 2:
The system implements feedback control by continuously measuring the actual coil spring position and using this information to adjust the application position. The control unit calculates the application position based on the measured actual position, creating a closed-loop system that compensates for dimensional variations
2Manufacturing precision
If the measurement position and application position are shifted by a specific angle, then the system can compensate for coil spring variations, but the control system becomes more complex
Solution Approach 1:
The system introduces an angular dimension to the control system by shifting the measurement position and application position by a specific angle relative to each other. This angular offset creates a geometric relationship that allows the system to compensate for coil spring variations while maintaining a relatively simple control algorithm based on coordinate transformation
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
Enables precise application of coating materials to coil springs, even with large tolerances, by calculating and timing application positions accurately, reducing positional deviations and enhancing adhesion through surface treatment.
Implementation Method 1
a sensor configured to measure a position of a strand of the coil spring
Implementation Method 2
using laser light to profile the coil spring
Data Source
AI summary
A coating material application system includes: a support base configured to rotatably support a coil spring; a sensor configured to measure a position of a strand of the coil spring; a first movement device configured to move the sensor; an application device; a second movement device configured to move the application device; and a control device. The control device is configured to: rotate the support base; a sensor control unit configured to acquire a measurement value of the sensor; move the sensor; calculate, based on a measurement value of the sensor, a position of application of a coating material to the coil spring; move the application device to a position where the application device is caused to apply the coating material to the position of application; and cause the application device to apply the coating material to the position of application.