Coil Spring Coiling Machine With Radial Wire Cutting Support
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional coiling machines face difficulties in cutting large-diameter or high-hardness wires, as they require excessive movement and time for cutting, leading to increased abrasion and damage to cutting tools, and necessitate a chuck corresponding to the coil diameter for stopping the movement.
Innovation Solution
A coiling machine with a feed roller, wire guide, forming rollers, pitch tool, support mechanism, and cutting rotor that cuts the wire in the radial direction, utilizing a clamping tool and support member to securely hold the wire during cutting, reducing movement and time required for cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a disc-shaped grinding stone is used to cut the wire in the radial direction of the coil spring, then the wire can be cut, but the amount of movement required increases and the cutting time becomes longer
Solution Approach 1:
Instead of moving the cutting tool in the coil radial direction (conventional approach), the patent inverts the approach by cutting the wire in the wire radial direction. The cutting rotor with blades rotates to cut the wire radially, similar to how a paper cutter works, thereby eliminating the need for large radial movements and reducing cutting time significantly.
Solution Approach 2:
The patent replaces the conventional disc-shaped grinding stone with a cutting rotor equipped with blades. This mechanical substitution allows for more efficient cutting by using rotating blades that can cut through the wire in its radial direction, rather than using a grinding stone that requires radial movement in the coil direction.
2Reliability
If the wire is cut in the coil diameter direction, then the wire can be severed, but the cut area becomes larger and the abrasion of the cutting tool increases
Solution Approach 1:
The patent inverts the cutting direction from coil radial direction to wire radial direction. By cutting along the wire's radial direction using the rotating cutting rotor, the cut area is minimized to a narrow line rather than a large surface area, thereby reducing tool abrasion and extending tool life.
3Device complexity
If a conventional cutter is used to shear the wire, then the cutting process is simple, but large-diameter or high-hardness wires cannot be cut effectively
Solution Approach 1:
The patent replaces the simple shearing cutter with a cutting rotor equipped with hardened blades. This mechanical substitution enables the system to cut through large-diameter and high-hardness wires that cannot be severed by conventional cutters, while the rotating blade mechanism remains relatively simple in design and operation.
Solution Approach 2:
The patent changes the cutting parameters by using a rotating blade system instead of a stationary shearing cutter. The rotation of the cutting rotor provides continuous cutting action with varying contact points, enabling effective cutting of materials that are too large or too hard for conventional static cutting tools.
4Device complexity
If the wire is not supported during cutting, then the cutting process is simpler, but the wire movement causes reduced cutting precision
Solution Approach 1:
The patent introduces a support mechanism as an intermediary between the wire and the cutting rotor. This support mechanism holds the wire steady during the cutting process, preventing unwanted movement and ensuring precise cutting. The support acts as a mediator that enables accurate cutting without adding significant complexity to the overall system.
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, while securely supporting the wire with the support mechanism, reducing tool wear and improving cutting precision.
Implementation Method 1
both end (distal end and rear end) of the wire is comprised a circular grinding cut surface, which is cut in the radial direction of the wire by grinding
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A coiling machine (10) includes feed rollers (11a, 11b) for moving a wire (1), a wire guide (12), a first forming roller (13), a second forming roller (14), a pitch tool (21), a cutting mechanism (23), and a support mechanism (24) for supporting the wire (1). The cutting mechanism (23) includes a cutting rotor (22). The wire (1) coming out of the wire guide (12) is formed into a helical shape by the first forming roller (13), the second forming roller (14) and the pitch tool (21). After one coil spring of a predetermined length is formed, the wire (1) is cut by moving the cutting rotor (22) in the radial direction of the wire (1). The cutting rotor (22) cuts the wire (1) supported by the support mechanism (24) in the radial direction of the wire (1) between the second forming roller (14) and the pitch tool (21).