Coil Spring Coiling Machine With Radial Wire Cutting
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Solution Overview
Problem
Conventional coiling machines face difficulties in cutting large-diameter or high-hardness wires, as they require excessive movement and time, leading to cutter damage and increased abrasion, especially when cutting in the coil diameter direction.
Innovation Solution
A coiling machine design that includes a feed roller, wire guide, forming rollers, a pitch tool, and a support mechanism with a cutting rotor, allowing for wire cutting in the radial direction, reducing movement and time required, and using a support mechanism like clamping tools or a V-shaped recess to securely hold the wire during cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional cutter is used to cut large-diameter or high-hardness wires, then the cutting operation can be performed, but the cutter is easily damaged and the wire cannot be properly cut
Solution Approach 1:
The patent replaces the conventional mechanical cutter with a disc-shaped grinding stone that uses abrasion to cut the wire. The grinding stone rotates at high speed and grinds through the wire end turn portion, eliminating the need for mechanical shearing that damages conventional cutters when dealing with large-diameter or high-hardness wires.
Solution Approach 2:
The patent changes the cutting mechanism from mechanical shearing to abrasive grinding. The grinding stone's rotational speed, abrasive grain composition, and contact pressure are controlled to achieve effective cutting of difficult materials without damaging the cutting tool.
2Manufacturing precision
If the disc-shaped grinding stone moves in the radial direction of the coil spring to cut the wire, then the end turn portion can be cut and ground, but the amount of movement is great and the cutting time is long
Solution Approach 1:
The patent changes the cutting direction from the coil radial direction to the wire radial direction. By orienting the grinding stone to cut along the wire's radial direction rather than moving radially across the coil, the travel distance is significantly reduced, thereby increasing cutting speed while maintaining cut quality.
3Manufacturing precision
If the wire is cut in the coil diameter direction, then the end turn portion can be removed, but the cut area is larger and the abrasion of the grinding stone is increased
Solution Approach 1:
The patent changes the cutting orientation from coil diameter direction to wire radial direction. This dimensional change reduces the contact area between the grinding stone and wire, minimizing abrasive wear on the grinding stone while still achieving precise end turn removal.
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 machine efficiently cuts helically formed coil springs in the radial direction, minimizing movement and time, and produces circular grinding cut surfaces, reducing cutter wear and improving cutting precision and speed.
Implementation Method 1
cutting means using a disc-shaped grinding stone has been proposed. The cutting means are equipped with two functions: one is to cut an end turn portion of the end of a formed coil spring
Data Source
AI summary
A coiling machine includes feed rollers for moving a wire, a wire guide, a first forming roller, a second forming roller, a pitch tool, a cutting mechanism, and a support mechanism for supporting the wire. The cutting mechanism includes a cutting rotor. The wire coming out of the wire guide is formed into a helical shape by the first forming roller, the second forming roller and the pitch tool. After one coil spring of a predetermined length is formed, the wire is cut by moving the cutting rotor in the radial direction of the wire. The cutting rotor cuts the wire supported by the support mechanism in the radial direction of the wire between the second forming roller and the pitch tool.