Helical Spring Winding Correction via Geometry Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current spring winding machines face challenges in quickly and efficiently correcting manufacturing parameters to meet stringent quality requirements, particularly in producing helical springs with specific geometry tolerances, which can lead to inefficiencies and increased production time.
Innovation Solution
A method and system for numerically controlled spring winding machines that involve measuring actual spring geometry, comparing it to nominal data, analyzing discrepancies, and generating correction data to adjust actuating movements and the NC control program, allowing for precise correction of spring geometry parameters, such as pitch and diameter, to ensure production within tolerance limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual trial and error methods are used to correct NC control programs, then flexibility in adjusting spring geometry is maintained, but correction time and production setup time increase significantly
Solution Approach 1:
The system measures actual spring geometry parameters and feeds this information back to automatically adjust the NC control program. The correction device receives measurement data about discrepancies between actual and nominal spring geometry, then automatically calculates and applies corrections to the control program, eliminating manual trial-and-error adjustment cycles.
Solution Approach 2:
The patent replaces manual mechanical adjustment methods with an automated computer-based correction system. Instead of operators physically adjusting machine parameters through trial and error, the system uses measurement data processed by a correction device that automatically generates corrected NC control programs, substituting human mechanical adjustment with automated computational correction.
2Manufacturing precision
If comprehensive measurement and correction of all spring sections is performed, then manufacturing precision is improved, but device complexity and processing time increase
Solution Approach 1:
The correction device identifies and focuses corrections on specific spring sections where geometry discrepancies exceed predetermined tolerances, rather than uniformly correcting all sections. The system selectively applies corrections to localized problem areas, reducing unnecessary processing complexity while maintaining overall manufacturing precision.
Solution Approach 2:
The spring is divided into multiple sections along its length, with each section independently evaluated against tolerance criteria. The correction system processes and corrects only those sections that fail to meet specifications, segmenting the correction task into manageable portions rather than treating the entire spring as a single correction unit.
3Manufacturing precision
If frequent corrections to NC control programs are made to meet quality requirements, then manufacturing precision improves, but productivity decreases due to repeated setup adjustments
Solution Approach 1:
The system enables continuous production by automatically correcting NC control programs without interrupting the manufacturing flow. Instead of stopping production for manual adjustments and setup changes, the correction device processes measurement data and updates control parameters in real-time or between minimal interruptions, maintaining continuous productive action.
Solution Approach 2:
The correction system is self-operating, automatically measuring spring geometry, identifying discrepancies, calculating corrections, and updating the NC control program without requiring operator intervention. This self-service capability eliminates the need for skilled technicians to perform repeated setup adjustments, maintaining productivity while ensuring quality compliance.
Data Source
AI summary
A method of producing helical springs by spring winding with a numerically controlled spring winding machine includes feeding a wire, controlled by an NC control program, through a feed device to a forming device of the spring winding machine, forming a helical spring from the wire with the forming device, measuring an actual geometry of the helical spring to obtain actual spring data, comparing the actual spring data with nominal spring data to determine discrepancy data which represents a discrepancy between an actual geometry and a predetermined nominal geometry of the helical spring for at least one spring geometry parameter, analyzing the discrepancy data and producing correction data when discrepancies are outside selected predetermined tolerance limits, varying an actuating movement of at least a portion of the forming device on the basis of the correction data for producing a next helical spring, selecting a spring section, determining a correction value for an actuating movement of a portion of the forming device, which correction value influences a spring geometry parameter in the selected spring section, and correcting the NC control program based on the correction value.