Coil Spring Coiling with Laser-Heated Wire Cutting
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Solution Overview
Problem
Existing coiling machines for manufacturing coil springs face challenges in achieving stable formation accuracy due to inadequate responsiveness of high-frequency heating, potential damage to cutting tools, and issues with laser cutting such as spatter and uneven irradiation.
Innovation Solution
A coiling machine equipped with a laser heater that emits laser light to heat a portion of the wire, followed by a cutting unit that cuts the heated site using a cutter, with an output density of laser light between 10 W/mm² and 100 W/mm², optimally between 31 W/mm² and 74 W/mm², to achieve efficient cutting and improved spring shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high-frequency heating is used to heat the cut site, then the wire can be softened for cutting, but the responsiveness of heating is poor and the cutting process becomes slow
Solution Approach 1:
The patent replaces the mechanical high-frequency heating system with a laser heating system. The laser beam directly heats the cut site with rapid response, eliminating the slow thermal diffusion process of conventional high-frequency heating. This substitution of heating mechanism resolves the contradiction by providing both the necessary temperature rise and fast responsiveness.
Solution Approach 2:
The patent changes the heating method from indirect high-frequency induction heating to direct laser beam heating. This parameter change in the heating mechanism enables rapid localized heating of the cut site, improving both the speed of heating and the overall cutting productivity while maintaining the necessary temperature for cutting.
2Temperature
If high-frequency heating is continued during cutting, then the wire remains softened, but the cutting members are affected by heat and may be damaged
Solution Approach 1:
The patent extracts the heating function from the cutting process itself. The laser heating is applied separately before cutting, and the heating source is removed once cutting begins. This separation ensures the wire remains heated for cutting while preventing heat transfer to the cutting members, eliminating the harmful thermal effect on the cutters.
Solution Approach 2:
The patent uses the laser beam as an intermediary heating source that can be precisely controlled and removed. The laser heats the wire to the required temperature, then is withdrawn before cutting commences. This intermediary approach allows the wire to reach the necessary temperature without continuously exposing the cutting members to heat, preventing thermal damage.
3Productivity
If laser light is used to cut the wire directly, then cutting can be achieved, but sputter occurs and laser light may be applied to other units causing interference
Solution Approach 1:
The patent applies preliminary heating action with the laser beam before the cutting operation. The wire is heated to the appropriate temperature, then the laser is removed and mechanical cutting is performed. This preliminary action achieves the softening effect needed for clean cutting without the harmful sputter and interference problems of direct laser cutting, while maintaining high productivity.
4Productivity
If the wire is cut in a partially heated state, then cutting can proceed, but the formation accuracy of the spring becomes unstable
Solution Approach 1:
The patent implements feedback control in the heating process. The laser heating parameters are controlled to achieve the precise temperature required for optimal cutting and spring formation. This feedback mechanism ensures the wire is heated to the correct degree before cutting, stabilizing the spring formation accuracy while maintaining high cutting speed through efficient laser heating.
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
The proposed solution enhances manufacturing efficiency and achieves a better shape quality of coil springs by ensuring precise cutting with reduced shear force and improved thermal management, thereby stabilizing the spring formation process.
Implementation Method 1
a laser heater configured to emit laser light to a wire formed into a helical shape, thereby heating a portion of the wire
Data Source
AI summary
A coiling machine comprises a laser heater which emits laser light to a wire formed into a helical shape, thereby heating a portion of the wire, and a cutting unit which cuts a site of the wire heated by irradiation with the laser light. An output density of the laser light is greater than or equal to 10 W/mm2 and less than or equal to 100 W/mm2.