Pneumatic Coil Spring Transfer to Prevent Rebound Collisions
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Solution Overview
Problem
Existing coil spring manufacturing systems face challenges in achieving trouble-free long-term operation with high output due to issues such as coil spring rebound during transport, leading to collisions and disruptions in the process flow.
Innovation Solution
A method and system for producing coil springs that incorporate a collision-proof spring transfer system, featuring a continuous transfer of coil springs through a pneumatic conveyor system with an automatic prevention of re-entry of recoiled springs, utilizing a braking device and a diameter-variable outlet opening to ensure smooth and controlled transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If coil springs are transported at high speeds through the pneumatic conveyor system, then productivity and unit output are improved, but coil springs may rebound and collide causing disruptions
Solution Approach 1:
A blocking device is introduced as an intermediary element in the pneumatic conveyor system. This blocking device temporarily obstructs the conveyor path to prevent recoiled springs from re-entering the conveyor, thereby resolving the conflict between high-speed transport and process reliability by mediating the interaction between transported springs and the conveyor system
Solution Approach 2:
The blocking device applies preliminary anti-action by preventing the harmful rebound effect before it can cause collisions and disruptions. By blocking the re-entry path of recoiled springs, the system counteracts the potential harmful effect of spring rebound before it can impact process continuity
2Productivity
If the pneumatic conveyor system continuously transports coil springs, then productivity is improved, but recoiled springs may re-enter the conveyor causing collisions
Solution Approach 1:
The blocking device serves as an intermediary that intercepts recoiled springs before they can re-enter the conveyor system. This mediator prevents the harmful interaction between discharged springs and the continuous transport flow, enabling both continuous operation and collision prevention
Solution Approach 2:
The blocking device extracts or removes recoiled springs from the potential re-entry path into the conveyor system. By taking out the problematic recoiled springs from the continuous transport flow, the system maintains continuous operation while preventing harmful re-entry collisions
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 system achieves a practically trouble-free operation at high unit outputs and transport speeds by preventing coil spring collisions and ensuring continuous, controlled transfer of coil springs, thereby enhancing process reliability and productivity.
Implementation Method 1
The pneumatic conveying system has a pressurized fluid acceleration device behind an inlet opening of the pipeline, which serves to accelerate the coil springs in the transport direction within the pipeline
Implementation Method 2
The pressurized conveying fluid, usually compressed air, serves both to separate the coil springs inserted one after the other through the feed opening and to transport the coil springs through the pipeline
Data Source
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AI summary
In a process for manufacturing helical springs from wire, wire is fed from a wire supply to a numerically controlled spring coiling machine. Sections of wire are successively formed into helical springs in the coiling machine. After the forming operation, each helical spring is separated from the supplied wire, and the separated springs are then successively transported through a pneumatic conveying system into a spring holder of a subsequent machine. This process employs collision-protected spring transfer, which includes the continuous transfer of helical springs from the pipeline through an outlet opening in the pipeline into their designated spring holders and the automatic prevention of springs that have passed through the outlet opening towards the spring holder and rebounded from the spring holder area back into the pipeline.The invention also relates to a system for the manufacture of coil springs.