Coil Spring Wire Laser Heating for Precise Low-Wear Cutting
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Solution Overview
Problem
Existing coil spring manufacturing technologies face challenges with heating responsiveness and accuracy, leading to inconsistent spring formation and potential damage to cutting tools due to high-frequency heating, and high-power laser cutting can result in spatter and reduced precision.
Innovation Solution
A coiling machine that uses laser heating to soften a portion of the wire, allowing for precise cutting after the laser light is stopped, creating a quench-hardened zone and heat-affected zone for improved cutting efficiency and accuracy, reducing the shearing force required and minimizing tool wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If high-frequency heating is used to soften the cutting portion, then the wire can be cut, but the responsiveness of heating is poor and cutting members are adversely affected
Solution Approach 1:
The patent replaces high-frequency heating (electromagnetic induction heating) with laser heating (optical energy conversion to thermal energy). The laser beam directly heats the cutting portion of the wire with high responsiveness and precision, avoiding the poor heating responsiveness and tool damage issues associated with high-frequency heating methods.
Solution Approach 2:
The patent changes the heating method from high-frequency electromagnetic induction to laser heating, altering the physical parameter of energy delivery. This enables precise control of heating temperature and duration, achieving optimal softening without adversely affecting cutting members.
2Productivity
If high-power laser light is used to cut the wire, then cutting speed is improved, but spatter occurs and precision is reduced
Solution Approach 1:
The patent applies partial laser heating - only the cutting portion of the wire is heated to the softening temperature, not the entire wire. This localized heating achieves sufficient softening for easy cutting while avoiding excessive heat input that would cause spatter and precision loss. The laser parameters are optimized to deliver just enough energy for the specific cutting requirement.
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 enables easy cutting of helical wires with improved spring quality, reduced tool wear, and lower operational costs by selectively heating and rapidly cooling the wire, maintaining shape accuracy and reducing spatter and dross formation.
Implementation Method 1
a laser heating machine configured to irradiate a wire formed into a helical shape with laser light to thereby heat a part of the wire
Implementation Method 2
the first end includes a first irradiation scar of laser light, the first irradiation scar includes a quench-hardened zone the hardness of which is higher than a base material of the wire
Data Source
AI summary
A coiling machine includes a laser heating machine configured to irradiate a wire formed into a helical shape with laser light to thereby heat a part of the wire, and cutting components configured to cut a portion of the wire after the irradiation of the laser light is stopped, a temperature of the portion being higher than before irradiated with the laser light.