Magnetic Coil Spring Transfer for Precise Pocketed Assembly

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Solution Overview

Problem

Existing pocketed spring assembly machines face challenges in efficiently and precisely transferring coil springs from a coil winding device to a conveyor belt, leading to complexity and unsatisfactory assembly speed or precision.

Innovation Solution

A mechanism utilizing a magnetic lift platform and a drive mechanism with a crank drive, combined with a slider for pushing the coil springs onto the conveyor belt, allowing for vertical acceleration exceeding gravity acceleration and precise alignment without mechanical gripping or rotation, enabling efficient and reliable transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If complex mechanical handling mechanisms are used to transfer coil springs, then the transfer can be achieved, but the machine complexity increases and assembly speed decreases

Engineering Contradiction:

Improvetransfer reliabilityVSAvoidmachine complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical gripping and rotation mechanisms with a magnetic field-based transfer system. The magnetic conveyor belt and magnetic engagement features create reliable coil spring transfer through magnetic attraction and release, eliminating the need for mechanical grippers, clamps, or rotation devices while improving transfer reliability and simplifying the overall machine structure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a magnetic field as an intermediary between the conveyor belt and coil springs. The magnetic conveyor belt with embedded magnets creates a magnetic field that engages with magnetic engagement features on the coil springs, enabling reliable transfer without direct mechanical contact. This intermediary magnetic field resolves the contradiction by providing reliable transfer through non-mechanical means.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If complex mechanical handling mechanisms are used to transfer coil springs, then the transfer can be achieved, but the assembly speed becomes unsatisfactory

Engineering Contradiction:

Improvetransfer reliabilityVSAvoidassembly speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The magnetic field-based transfer system enables faster assembly speeds compared to mechanical mechanisms. The magnetic engagement and release can occur rapidly without the inertia and mechanical wear limitations of mechanical grippers and actuators, allowing higher throughput while maintaining reliable transfer of coil springs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The magnetic conveyor belt operates with periodic engagement and release cycles. The magnetic field is activated to engage coil springs during transfer, then deactivated or repositioned to release them at the destination. This periodic magnetic action enables rapid, high-speed transfer cycles that improve assembly productivity while maintaining reliability.

Inventive Principle:

Principle #19Periodic action

3Manufacturing precision

If mechanical gripping mechanisms are used to handle coil springs, then the transfer can be achieved, but the precision and speed of assembly are compromised

Engineering Contradiction:

Improveassembly precisionVSAvoidassembly speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The magnetic field-based transfer system provides both high precision and high speed simultaneously, resolving the trade-off between precision and productivity. The magnetic field can precisely control the position and orientation of coil springs during transfer through field distribution patterns, while the absence of mechanical inertia enables rapid transfer cycles. The magnetic engagement ensures accurate positioning without the speed limitations of mechanical actuators.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enhances the reliability and speed of coil spring transfer, ensuring precise alignment and efficient operation of the pocketed spring assembly machine by using magnetic engagement and vertical acceleration, thereby improving assembly precision and speed.

Implementation Method 1

engaging the coil spring on a magnetic lift platform

Methodology Applied

Scientific EffectMagnetic engagement: Magnetism

Implementation Method 2

moving the lift platform with vertical acceleration higher than gravity acceleration

Methodology Applied

Scientific EffectVertical acceleration: Gravitation

Data Source

PatentUS12162696B2Method for transferring coil springs from a coil winding device to a conveyor belt of a pocketed coil assembly machine

Publication Date: 2024.12.10 SPUHL GMBH

AI summary

A mechanism for transferring coil springs from a coil winding device to a conveyor belt of a pocketed coil assembly machine comprises a magnetic lift platform for engaging a coil spring before being released at an output of the coil winding device. Further, the mechanism comprises a drive mechanism for moving the lift platform between the output of the coil winding device and the conveyor belt.