Helical Disc Spring Assembly Tool for Screwed Compression Springs
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Solution Overview
Problem
The industrial production and use of disc springs are associated with high material and labor costs, and are time-consuming for assembly and maintenance due to the large number of individual discs, with unfavorable fiber flow leading to fractures.
Innovation Solution
A tool and system for screwing helical disc springs, comprising two tools with a claw and stop arrangement, allowing for the rotation of one helical compression spring while the other remains stationary, enabling the screwing of two helical compression springs into a single helical disc spring, with adjustable features to accommodate different diameters and orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional disc springs are used, then the spring can provide the required force, but the assembly and maintenance are time-consuming due to the large number of individual discs
Solution Approach 1:
The patent combines multiple individual disc springs into a single helical disc spring formed from one continuous strip of material. This merging reduces the number of separate components from multiple discs to a single integrated spring element, thereby simplifying assembly and maintenance operations while maintaining the required force output.
Solution Approach 2:
The helical disc spring is segmented into two identical helical compression springs that are screwed into one another. This segmentation allows the spring to be manufactured from a continuous strip in a more efficient manner while still providing the functional equivalent of multiple stacked discs, improving productivity without sacrificing performance.
2Ease of manufacture
If traditional disc springs are used, then the spring can provide the required force, but the material and labor costs are high
Solution Approach 1:
By merging multiple disc spring functions into a single helical disc spring made from one continuous strip, the patent reduces material waste associated with assembling multiple separate discs. The continuous strip can be manufactured more efficiently with less material handling and joining operations, thereby reducing both material and labor costs.
Solution Approach 2:
The patent changes the geometric parameters of the spring from multiple flat discs to a helical configuration with varying cross-sections along its length. This parameter change allows for more efficient material utilization and manufacturing processes, reducing overall production costs while maintaining the required mechanical properties.
3Reliability
If traditional disc springs are used, then the spring can provide the required force, but the unfavorable fiber flow leads to fractures
Solution Approach 1:
The patent introduces a helical curvature to the disc spring, transforming it from flat circular discs to a three-dimensional helical structure. This curvature allows the material fibers to flow more naturally along the helical path, reducing stress concentrations and the likelihood of fractures, thereby improving reliability and breakage resistance.
Solution Approach 2:
The helical disc spring can be manufactured from composite materials or strips with optimized fiber orientations that follow the helical path. This allows the material composition to be tailored for enhanced breakage resistance while maintaining the favorable fiber flow along the curved trajectory of the helix.
Data Source
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AI summary
The arrangement has two tools (1) comprising respective cylindrical tool bodies (2). The tool bodies comprise a transit (3) for receiving a cylindrical arbor (5). The transit is arranged concentric to a rotational axis (7) around which one tool rotates opposite to another tool. A claw (12) is formed adjacent to the transit at an end surface (9), for clamping an end of a helical compression spring. The claw comprises a projection in a rotational direction. The arbor partially exhibits a constant cross-section. The spring is fitted on an outer surface of the arbor with small clearance. Independent claims are also included for the following: (1) a system for fastening a helical compression spring to a helical plate spring (2) a method for fastening a helical compression spring to a helical plate spring.