Coil Spring Manufacturing Roll Tilting for Pitch Control
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Solution Overview
Problem
Conventional coil-spring manufacturing machines using rolls face challenges in accurately shaping coil springs with varying pitches, particularly in achieving a desired pitch change, as the coil wire material may detach from the pitch tool or fail to follow its movement, leading to abrupt pitch changes and difficulties in forming coils with negative pitches.
Innovation Solution
The apparatus comprises a first and second shaping roll, a supporting roll, and a pitch tool, where the rolls are movable along the conveying direction and the second roll is tiltable and movable in the screwing direction, allowing for precise control of pitch formation by applying deformation forces to shape the coil wire material effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the pitch tool is greatly pushed out in the screwing direction to increase the pitch, then the pitch can be increased, but the coil wire material may come apart from the pitch tool and cannot follow the movement of the pitch tool, leading to abrupt pitch changes
Solution Approach 1:
The second roll is made movable in the screwing direction and tiltable about its axial line, allowing the rolling section to dynamically adjust its position and orientation. This dynamic configuration enables the rolling section to maintain proper engagement with the coil wire material during pitch changes, preventing the material from detaching while achieving the desired pitch variations.
Solution Approach 2:
The movable and tiltable second roll acts as an intermediary between the pitch tool and the coil wire material. By adjusting the position and angle of the second roll, the system mediates the interaction between the pitch tool's pushing action and the material's resistance, ensuring continuous contact and controlled deformation without abrupt pitch changes.
2Manufacturing precision
If the pitch tool is abruptly moved back to decrease the pitch, then the pitch can be reduced, but the coil wire material may not follow the backward movement of the pitch tool, making it difficult to shape coil springs with negative pitches accurately
Solution Approach 1:
The second roll's ability to move and tilt dynamically allows it to adapt to both forward and backward movements of the pitch tool. When the pitch tool moves back, the second roll can adjust its position and angle to maintain engagement with the material, enabling accurate control of pitch reduction and the formation of negative pitches that were previously difficult to achieve.
Solution Approach 2:
The system changes the operational parameters of the second roll (position in screwing direction and tilt angle) to match the required pitch variations. By adjusting these parameters, the system can accommodate a wide range of pitch changes including negative pitches, enhancing both precision and adaptability.
3Manufacturing precision
If two shaping rolls are arranged bilaterally symmetrical about the supporting roll to shape the coil wire material, then the coil spring can be manufactured with controlled outer diameter and pitch, but the system becomes complex and difficult to adjust for varying pitch requirements
Solution Approach 1:
The second roll is configured to be movable in the screwing direction and tiltable about its axial line, transforming a static symmetric arrangement into a dynamic system. This dynamic configuration maintains the benefits of symmetric arrangement for dimensional control while adding adjustability for varying pitch requirements, reducing operational complexity despite increased structural capability.
Solution Approach 2:
The second roll serves multiple functions: it maintains the symmetric arrangement for outer diameter control, moves in the screwing direction for pitch adjustment, and tilts to accommodate various pitch configurations including negative pitches. This multi-functionality reduces the need for additional specialized components, simplifying the overall system while maintaining precision.
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
This configuration enables the formation of coil springs with desired pitch changes, including large variations, by applying forces in the direction of pitch reduction and tilting to grasp the coil wire material, ensuring accurate shaping regardless of pitch magnitude or sign.
Implementation Method 1
a first roll (shaping roll) and a second roll (shaping roll) arranged on a side of a conveying direction of a coil wire material, along the conveying direction, and a third roll (support roll) arranged between the first and second rolls opposed to the first and second rolls... By the first to third rolls, the coil wire material is bent in a circumferential direction of the coil spring
Implementation Method 2
a pitch tool which pushes out the coil wire material bent and shaped in a screwing direction of the coil spring to shape... The pitch tool pushes out the coil wire material and can thus easily increase the pitch
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A coil wire material (30) is bent by a first roll (32), a second roll (34), and a third roll (36). The bent coil wire material (30) is pressed in a screwing direction, to shape a coil spring having a desired diameter and a pitch. A desired pitch can be accurately formed in a manner that a second roll (34) provided on a downstream side of a conveying direction of the coil wire material (30) is configured to be able to move back and forth along the screwing direction of the coil spring and to be tiltable about an axis of rotation parallel to the conveying direction of the coil wire material (30).