Coil Spring Pigtail Forming with Axial Pitch Adjustment
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Solution Overview
Problem
Existing coil spring forming devices cannot adjust the pitch of the end wound portion, resulting in an inability to set the desired pitch during the additional processing stage, leading to unsatisfactory final product specifications.
Innovation Solution
A coil spring forming method and device that allow for the clamping and relative movement of the wire end in the axis direction, enabling adjustment of the inter-wire distance and pitch of the end wound portion by utilizing a first clamp, a second clamp, and a moving mechanism driven by a controller, allowing for arbitrary direction bending and fine accuracy in forming the coil spring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the rotating shaft is moved only within the plane orthogonal to the rotational axis when forming a pigtail, then the forming process is simple, but the pitch of the end wound portion cannot be adjusted from the pitch made when the semi-finished product was formed
Solution Approach 1:
The patent applies the dynamics principle by enabling the rotating shaft to move not only within the plane orthogonal to the rotational axis but also in the axial direction. This dynamic movement capability allows the pitch of the end wound portion to be adjusted during the pigtail forming process, resolving the contradiction between process simplicity and pitch adjustment capability. The shaft's ability to move axially while rotating enables real-time control over the winding pitch.
Solution Approach 2:
The patent introduces movement in another dimension (axial direction) in addition to the original planar movement orthogonal to the rotational axis. This dimensional expansion allows the forming device to control both the radial positioning and axial positioning of the wire during winding, thereby achieving pitch adjustment while maintaining relatively simple device architecture.
2Productivity
If the pitch of the end wound portion is set during semi-finished product formation, then the initial coiling is efficient, but the final pitch requirement cannot be met when additional processing is needed
Solution Approach 1:
The patent enables dynamic pitch adjustment during the additional processing stage by allowing the rotating shaft to move in the axial direction. This means the initial coiling can be performed efficiently with a fixed setup, and then the pitch can be dynamically adjusted during the pigtail forming process to meet the final pitch requirements, thus resolving the contradiction between initial coiling efficiency and final pitch accuracy.
Solution Approach 2:
The patent performs preliminary coiling to create the semi-finished cylindrical product efficiently, then uses the additional processing stage with axial movement capability to make precise pitch adjustments. This two-stage approach with preliminary action followed by refinement allows both high productivity in the first stage and high precision in the second stage.
Data Source
AI summary
A method for forming a wire into a coil spring includes winding the wire around a coiling mandrel to form the wire into a cylindrical coil shape, clamping one end of the wire formed into the cylindrical coil shape, clamping an intermediate portion of the wire spaced from the clamped one end of the wire; and moving the clamped one end of the wire relative to the clamped intermediate position at least in an axis direction of the cylindrical coil shape, whereby a pigtail having a desired shape is formed.