Coil Spring Forming with Servo-Driven Rollers for Weak Wire Rods
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Solution Overview
Problem
In coil spring manufacturing, the rotating body's frictional force against the support tool limits the types of wire rods that can be used, as weaker wire rods may slip and fail to rotate the body, leading to low-quality coil springs or difficulty in forming.
Innovation Solution
The rotating body is driven by a rotary drive source to rotate in synchronization with the wire rod's feed, eliminating the need for frictional force between the rotating body and wire rod, allowing for precise formation with various wire rod strengths, including weaker ones, by matching the circumferential speed of the rotating body to the wire rod's feed speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the rotating body is rotated by frictional force between the wire rod and rotating body outer circumferential surface, then the wire rod strength requirement is increased, but the adaptability to various wire rod strengths is reduced
Solution Approach 1:
The patent replaces the friction-based mechanical rotation system with a direct drive system using a rotary drive source. The rotary drive source directly rotates the rotating body without relying on frictional force from the wire rod, thereby eliminating the requirement for high wire rod strength and enabling the use of wire rods with various strengths including weaker ones.
Solution Approach 2:
The patent introduces a rotary drive source as an intermediary between the control system and the rotating body. This intermediary component provides the rotational force needed to rotate the rotating body, eliminating the need for the wire rod to generate frictional force for rotation and thus resolving the contradiction between wire rod strength requirements and adaptability.
2Force
If the wire rod is pressed against the rotating body outer circumferential surface to generate frictional force, then the rotating body can rotate, but wire rods with insufficient strength will slip and fail to rotate the body
Solution Approach 1:
The patent replaces the friction-based force transmission system with a direct drive system. The rotary drive source directly applies rotational force to the rotating body, eliminating the need for frictional force between the wire rod and rotating body. This ensures reliable rotation of the rotating body regardless of wire rod strength, preventing slippage and ensuring consistent coil spring formation.
Solution Approach 2:
The patent extracts the frictional force generation function from the wire rod-rotating body interface and relocates it to a dedicated rotary drive source. This separation allows the rotating body to rotate reliably without depending on the wire rod's strength to generate sufficient frictional force, thereby improving the reliability of coil spring formation.
3Device complexity
If the rotating body rotates based on frictional force, then the system is simpler, but the manufacturing precision of coil spring is reduced due to wire rod slippage
Solution Approach 1:
The patent replaces the passive friction-based rotation system with an active direct drive system using a rotary drive source. This substitution eliminates wire rod slippage by directly controlling the rotation of the rotating body, thereby improving manufacturing precision of coil springs. The increase in device complexity is minimal and justified by the significant improvement in precision.
Solution Approach 2:
The rotary drive source acts as an intermediary that precisely controls the rotation of the rotating body. This intermediary component ensures synchronized rotation with the wire rod feed, eliminating slippage and improving manufacturing precision. The controlled rotation enables accurate coil spring formation regardless of wire rod strength variations.
4Force
If high wire rod strength is required to overcome static friction, then the rotating body can start rotating, but the range of usable wire rod types is limited
Solution Approach 1:
The patent replaces the friction-based force transmission system with a direct drive system using a rotary drive source. This substitution eliminates the need to overcome static friction between the wire rod and rotating body, as the rotary drive source directly applies rotational force. Consequently, the limitation on wire rod types based on strength requirements is removed, allowing the use of a wider range of wire rod types including weaker and coated wires.
Solution Approach 2:
The rotary drive source serves as an intermediary that provides the necessary rotational force independent of wire rod strength. This intermediary component decouples the rotation initiation process from the wire rod's frictional force generation capability, thereby expanding the range of usable wire rod types to include weaker wires and coated wires that would otherwise be unsuitable.
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 method enables precise and reliable coil spring formation with a wide range of wire rod strengths, preventing damage and ensuring consistent quality, even with coated wires, by reducing frictional forces and eliminating the need for high wire rod strength.
Implementation Method 1
a frictional force of the wire rod with respect to the rotating body outer circumferential surface exceeds a resistance force (maximum static frictional force) of the rotating body with respect to the support tool
Data Source
AI summary
A method of manufacturing a coil spring and a coil spring manufacturing apparatus are provided that enable precise forming of a coil spring even when various kinds of wire rods are used as a wire rod. This is based on the premise that the wire material being fed out is serially pressed against a rotating roller outer circumferential surface to form the wire rod into a coil shape. Under this premise, as the wire rod is fed out, a rotating roller is rotationally driven by a rotary drive force of a servomotor such that a portion pressed against the wire rod on the rotating roller outer circumferential surface moves toward the advancing side of the wire rod.