Linear Spring Forming Device with Paired Slide Plates
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Solution Overview
Problem
The existing linear-spring forming apparatus has dead angles where the spring forming tool cannot strike the linear material, limiting the formation of high-precision springs due to the significant separation of slide plates and the need for multiple servo-motors, which increases costs and does not completely eliminate dead angles.
Innovation Solution
The apparatus is designed with a reduced number of servo-motors by pairing neighboring slide plates with a single servo-motor and arranging slide plates closer together, allowing the rotatable table to be positioned for optimal striking of the linear material from any direction, using a rack-and-pinion or modified Geneva power transmission mechanism for smooth advancement and retraction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the number of slide plates is increased to eliminate dead angles, then manufacturing precision is improved, but device complexity and cost increase due to requiring more servo-motors
Solution Approach 1:
The patent combines the driving function for two neighboring slide plates into a single servo-motor through a differential mechanism. The servo-motor drives a differential gear mechanism that distributes motion to two slide plates simultaneously, reducing the total number of servo-motors from 16 (one per slide plate) to 8 (one per pair of slide plates), while maintaining the ability to eliminate dead angles through increased slide plate density
Solution Approach 2:
The differential mechanism serves multiple functions: it reduces the number of servo-motors required, enables synchronized movement of paired slide plates, and maintains independent controllability of each slide plate position. This multi-functional mechanism resolves the contradiction by making the servo-motor system more efficient while supporting the increased number of slide plates needed for high-precision spring formation
2Manufacturing precision
If slide plates are arranged closer together to eliminate dead angles, then manufacturing precision is improved, but the risk of interference between neighboring slide plates increases
Solution Approach 1:
The patent employs a rotatable table that can be dynamically positioned to rotate slide units about the quill axis. This dynamic positioning allows the system to optimize the angular positions of slide plates during operation, ensuring that even when slide plates are arranged closely together, they can be oriented to avoid interference while maintaining their ability to strike the linear material from any direction for high-precision spring formation
3Ease of operation
If multiple servo-motors are used to drive each slide plate independently, then ease of operation is improved, but cost increases significantly
Solution Approach 1:
The patent merges the control of two neighboring slide plates under a single servo-motor through a differential gear mechanism. Each servo-motor controls a pair of slide plates, reducing the total number of servo-motors by half while maintaining independent controllability. The differential mechanism allows each slide plate to be positioned independently while being driven by a common servo-motor, thus preserving ease of operation while reducing cost and complexity
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 configuration significantly reduces dead angles, decreases the number of servo-motors needed, and allows for the production of high-precision springs at a lower cost without generating friction or bending moments, enabling the spring forming tool to strike the linear material from any direction.
Implementation Method 1
a rack-and-pinion power transmission mechanism for smooth advancement and retraction
Implementation Method 2
a modified Geneva power transmission mechanism for smooth advancement and retraction
Data Source
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AI summary
OBJECT To provide a linear-spring forming apparatus having an increased number of slide plates with less number of servo-motors. MEANS FOR ACHIEVING THE OBJECT An inventive linear-spring forming apparatus has: a rotatable table (10) surrounding a quill (6) for guiding a linear material; a multiplicity of slide units (15) radially arranged on, and in the circumferential direction of, the rotatable table (10) at substantially equal angular intervals, each of the slide units (15) being slidable in the radial directions of the rotatable table; and a multiplicity of slide plates (33) arranged outside, and in the circumferential direction of, the rotatable table (10) at equal angular intervals, and aligned with the respective slide units (15) in radial directions such that each slide plate (33) can be driven by a servo-motor (M3) in the radially inward and outward directions, in such a way that a selected one of the slide plates (33) advances one of the associated slide unit (15) towards the axis of the quill at a right angle thereto until the tool mounted on the slide unit abuts against the linear material (41) fed from the leading end of the quill (6) to form a linear spring. The slide plates (33) are closely and radially arranged along the circumference of the rotatable table. Every two slide plates (33) neighboring in pairs are provided with one servo-motor for selectively driving the respective slide plates one at a time.