Coil Spring Wire Shape Processing for Variable Cross Sections
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Solution Overview
Problem
Existing shape measurement methods for coil springs with varying cross-sectional shapes fail to accurately measure and process wire data due to assumptions of uniform circularity, leading to inaccurate processing.
Innovation Solution
A system comprising a support mechanism, sensor, and control device that rotates the coil spring about its central axis, measures wire data, specifies cross-sectional shapes, and executes processing tailored to these shapes, using a virtual figure estimation and error calculation to ensure accurate application of coating material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If processing corresponding to a circle is executed with respect to wire data, then the measurement process is simplified, but measurement accuracy deteriorates for portions where the cross-sectional shape is not circular
Solution Approach 1:
The system dynamically adapts the processing method based on the detected cross-sectional shape. The shape specifying unit identifies whether the cross-section is circular or non-circular, and the processing execution unit automatically selects the appropriate processing correspondence (circle or non-circle). This dynamic adaptation resolves the contradiction by making the system flexible rather than fixed, achieving both simplicity through automation and accuracy through shape-specific processing.
Solution Approach 2:
The system changes the processing parameters based on the cross-sectional shape detection. When a non-circular cross-section is detected, the system switches from circle-corresponding processing to non-circle-corresponding processing. This parameter change allows the system to maintain measurement accuracy for various shapes while keeping the overall process manageable through automated parameter selection.
2Ease of manufacture
If a fixed circular processing method is used, then the processing method is standardized and easy to implement, but it cannot accurately measure varying cross-sectional shapes
Solution Approach 1:
The system transitions from a static, fixed processing method to a dynamic, adaptive one. The shape specifying unit detects the cross-sectional shape in real-time, and the processing execution unit automatically adjusts the processing correspondence accordingly. This maintains ease of implementation through automation while achieving versatility in handling different shapes.
Solution Approach 2:
The system performs self-adjustment based on the detected shape. The shape specifying unit and processing execution unit work together to automatically select the appropriate processing method without requiring manual intervention or pre-programming for each shape type. This self-service capability maintains implementation simplicity while achieving shape adaptability.
3Device complexity
If the cross-sectional shape is assumed to be circular, then the measurement process is simplified, but measurement accuracy deteriorates for portions where the cross-sectional shape varies
Solution Approach 1:
The shape specifying unit performs a preliminary detection of the cross-sectional shape before the main measurement processing. By identifying the shape type in advance, the system can then apply the appropriate processing correspondence, ensuring both accuracy for the specific shape and simplicity through automated preliminary classification.
Solution Approach 2:
The system dynamically selects the measurement approach based on the detected shape. Rather than assuming a fixed circular shape, the system adapts its measurement process to match the actual cross-sectional geometry, resolving the contradiction between process simplicity and measurement accuracy.
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
Enables accurate processing of wire data even when cross-sectional shapes vary, ensuring precise application of coating material and improving measurement accuracy.
Implementation Method 1
the surface of the coil spring is irradiated with linear slit light spreading in an axial direction of the coil spring fixed to a rotation stage, and the reflected light is photographed by a camera to acquire wire data
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A wire data processing system 1 includes a support mechanism 4 configured to support a coil spring W and enable the coil spring W to rotate about a specific axis Ax following the central axis of the coil spring W, a sensor 5 configured to measure the outer shape position of the wire of the coil spring W and output wire data, and a control device 3 configured to control the operations of the support mechanism 4 and the sensor 5. The control device 3 includes a support mechanism control unit configured to operate the support mechanism 4 and rotate the coil spring W about the specific axis Ax, a sensor control unit configured to operate the sensor 5 and acquire the wire data from the sensor 5, a shape specifying unit configured to specify a cross-sectional shape of the wire based on the wire data, and a processing execution unit configured to execute processing corresponding to the cross-sectional shape of the wire with respect to the wire data.