Helical Spring Winding Real-Time Pitch Control
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Solution Overview
Problem
Existing methods for producing helical springs struggle to maintain tight geometric tolerances and reduce scrap rates, especially for long springs, due to variations in wire quality and length, leading to inefficiencies and high waste in the manufacturing process.
Innovation Solution
Implementing a method where a numerically controlled spring winding machine measures the actual position of a structural element during production and adjusts the pitch tool in real-time to match the nominal geometry, using a camera-based optical measurement system to control the forming process and ensure accurate length and pitch within specified tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If measurement and automatic sorting is performed after spring completion, then quality requirements are met, but wire waste increases significantly for long springs
Solution Approach 1:
The patent performs measurement during the spring winding process rather than after completion. By measuring the position of structural elements at intermediate stages, the system can detect geometry deviations early and adjust manufacturing parameters before the entire spring is formed, preventing wire waste while ensuring quality compliance
Solution Approach 2:
The patent implements a feedback control system where measurement data from the winding process is used to automatically adjust manufacturing parameters. The measured position of structural elements is compared against target values, and deviations trigger automatic adjustments to winding parameters, enabling real-time quality control without post-processing sorting and wire disposal
2Loss of substance
If measurement and parameter adjustment is performed during manufacture, then wire waste is reduced, but device complexity increases
Solution Approach 1:
The patent employs a camera system that serves multiple functions: it captures images for measurement, provides visual documentation, and can potentially monitor other process aspects. This multi-functional approach reduces the need for dedicated specialized devices, thereby limiting the increase in overall system complexity while enabling continuous measurement and feedback control during spring manufacturing
3Manufacturing precision
If tight geometric tolerances are maintained for long springs, then product quality improves, but scrap rate increases due to wire consumption
Solution Approach 1:
The patent implements continuous feedback control during the winding process, where measured positions of structural elements are compared against target geometry, and deviations trigger automatic parameter adjustments. This real-time correction capability enables maintaining tight geometric tolerances while preventing scrap formation, as issues are corrected during manufacturing rather than detected after wire consumption is complete
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 approach significantly reduces length scatter and scrap rates, enabling the production of helical springs with consistent geometry and improved reliability, even with varying wire quality, by allowing for precise control of the spring geometry during the manufacturing process.
Implementation Method 1
an actual position of a structural element of the helical spring is measured relative to a reference element at least one measurement time, which occurs after a start and before an end of the production of the helical spring, in a measurement area which is at a finite distance from the forming device
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 tools of the forming device, defining a desired nominal geometry of the helical spring and an NC control program adapted to produce the nominal geometry, measuring an actual position of a selected structural element of the helical spring relative to a reference element at least one measurement time, which occurs after a start and before an end of production of the helical spring in a measurement area which is at a finite distance from the forming device in a longitudinal direction of the helical spring, wherein the distance is less than an overall length of the finished helical spring, comparing the actual position with a nominal position of the structural element for the measurement time to determine a current position difference, which represents a difference between an actual position and the nominal position at the measurement time, and controlling the position by at least one of the tools of the forming device, which tool determines a pitch of the helical spring as a function of the position difference.