Double Steel Wire Heating Control for Uniform Spring Coiling
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Solution Overview
Problem
The challenge in mattress spring production is achieving uniform and stable heat treatment temperatures for double steel wires with different diameters, which affects the quality and durability of mattresses due to frequent switching between steel wires during coiling.
Innovation Solution
A device and method incorporating a double steel wires coiling machine with two heating mechanisms and real-time temperature detection systems, including steel wire stabilizing members and infrared temperature sensors, controlled by a controller to ensure consistent heating of both steel wires, allowing for precise temperature management and efficient switching between them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a coiling machine for double steel wires is used to coil different springs with two types of steel wires at the same time, then production efficiency is improved, but heat treatment uniformity deteriorates due to frequent switching between steel wires
Solution Approach 1:
The heating system is segmented into two independent heating mechanisms, each dedicated to one steel wire. This allows each wire to be heated independently without interference from switching operations, maintaining heat treatment uniformity while enabling simultaneous coiling of both wires
Solution Approach 2:
The steel wires are pre-heated to the required temperature before coiling begins. This preliminary heating action ensures that when switching between steel wires occurs, both wires are already at the correct temperature, preventing heat treatment quality deterioration
2Productivity
If frequent switching between two types of steel wires is performed, then production efficiency is improved, but heat treatment stability deteriorates
Solution Approach 1:
Temperature detection mechanisms continuously monitor the temperature of both steel wires in real-time and provide feedback to the control system. This feedback mechanism ensures that switching between steel wires does not compromise temperature stability, as the system can detect and maintain consistent heating conditions
Solution Approach 2:
The heating mechanisms automatically maintain the required temperature for each steel wire through self-regulating control. This self-service capability ensures that even during frequent switching operations, each steel wire maintains stable temperature conditions without external intervention
3Manufacturing precision
If real-time temperature detection is implemented for both steel wires, then heat treatment quality is improved, but device complexity increases
Solution Approach 1:
The temperature detection mechanisms serve multiple functions: they monitor temperature in real-time, provide feedback for control, and enable automatic temperature maintenance. This multi-functionality justifies the added complexity by delivering comprehensive temperature management that ensures high heat treatment quality
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 solution ensures that both steel wires are heated uniformly, maintaining consistent heat treatment effects across all springs, thereby enhancing production quality and efficiency by maintaining temperatures within predetermined ranges.
Implementation Method 1
the temperature sensor includes an infrared temperature sensor
Implementation Method 2
two heating mechanisms for respectively heating two steel wires
Data Source
AI summary
Disclosed are a device and method for detecting heating treatment temperatures of double steel wires. The temperature detection device includes a double wires coiling machine, two heating mechanisms for respectively heating two steel wires, and two temperature detection mechanisms for respectively detecting temperatures of the two steel wires in real time, and a controller electrically connected to the two heating mechanisms and the double-wire spring coiling machine respectively.