Rotating Coil Spring Heating for Uniform Hardening
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Solution Overview
Problem
Existing heating methods for coil springs result in significant variations in coil diameters and spaces between coils during hardening, leading to inconsistent mechanical properties.
Innovation Solution
A heating method involving fixing one end of the coil spring to a first shaft member and another end to a second shaft member, then rotating both shafts in alignment with the coil's central axis at an angle of 0 to 30 degrees to the horizontal, with controlled temperature and rotation velocity to minimize coil diameter and space variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the coil spring is heated by being supported on a support plate with horizontal placement, then heating can be performed to improve mechanical properties, but diameters of coils and spaces between coils vary largely after hardening
Solution Approach 1:
The coil spring is rotated dynamically during heating instead of being held static on a support plate. The rotation is performed at a specific velocity range (1-10 rpm) to ensure uniform heat distribution across all coil surfaces, preventing localized overheating that causes dimensional variation. This dynamic heating approach maintains consistent coil diameters and spacing while achieving the required mechanical properties through uniform tempering.
Solution Approach 2:
The coil spring is pre-positioned on a support member with its central axis aligned to the rotation axis before heating begins. This preliminary positioning ensures that the spring is correctly oriented and supported during the subsequent rotation and heating process, preventing misalignment that could lead to uneven heating and dimensional inconsistency in the final product.
2Ease of manufacture
If the coil spring is heated in a static horizontal position, then the heating process is simple to implement, but uniform heating is difficult to achieve
Solution Approach 1:
The coil spring is rotated during heating to achieve uniform heat distribution across all surfaces. The rotation velocity is controlled within 1-10 rpm to ensure that heat is evenly distributed without causing mechanical stress or deformation. This dynamic approach maintains heating uniformity while keeping the process relatively simple through automated rotation control.
Solution Approach 2:
A support member with a specific structure is introduced as an intermediary between the heating source and the coil spring. The support member includes a rotation mechanism that facilitates uniform rotation during heating, ensuring consistent heat exposure while maintaining ease of manufacture through a relatively simple mechanical design.
3Device complexity
If the coil spring is heated without rotation, then the heating setup is simpler, but variation in coil dimensions increases
Solution Approach 1:
The coil spring is rotated during heating at a controlled velocity (1-10 rpm) to ensure uniform heat distribution and prevent dimensional variation. This rotation mechanism, while adding some complexity, is implemented through a simple support member design that keeps the overall system relatively uncomplicated while significantly improving manufacturing precision.
Solution Approach 2:
The coil spring is pre-positioned on the support member with proper alignment to the rotation axis before heating begins. This preliminary setup ensures that the spring is correctly oriented for uniform rotation and heating, minimizing the complexity of the heating system while maximizing dimensional consistency through proper initial configuration.
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 method ensures uniform heating and minimizes variations in coil diameters and spaces between coils, enhancing the mechanical properties of the coil spring.
Implementation Method 1
a heating step of energizing the first and second shaft members to heat up the coil spring
Data Source
AI summary
A heating method for hardening a coil spring includes: fixing one end of the coil spring to an outer peripheral surface of a first shaft member and fixing another end of the coil spring to an outer peripheral surface of a second shaft member; energizing the first and second shaft members to heat up the coil spring; and rotating each of the first and second shaft members in a state where the first and second shaft members are being energized. Rotation axes of the first and second shaft members are positioned on a same straight line that is at an angle of 0 degrees or more and 30 degrees or less to a horizontal direction, and a central axis of the coil spring that has been mounted on the first and second shaft members is parallel to the straight line.