Magnetic Spring Carrier for Fast Coil Spring Placement
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Solution Overview
Problem
The assembly of devices that include springs is inefficient due to the difficulty in accurately and repeatedly retrieving, moving, and placing springs, leading to potential errors and production stoppages in manufacturing processes.
Innovation Solution
A spring carrier with a magnetic member that magnetically attracts and retains coil springs within an elongate hollow body, allowing for secure handling and easy extraction using airflow, facilitating efficient and reliable retrieval and placement in manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If springs are stored or conveyed together in a bulk manner, then storage efficiency is improved, but spring entanglement occurs making separation difficult and time-consuming
Solution Approach 1:
The bulk spring storage is segmented into individual carrier units, each holding a single spring. This segmentation prevents entanglement while maintaining compact storage, allowing springs to be separated simply by removing individual carriers rather than disentangling bulk springs.
Solution Approach 2:
The carrier acts as an intermediary between the spring and the handling system. The carrier provides a structured interface that prevents spring entanglement during storage and conveyance, while enabling easy spring extraction at the assembly point without time-consuming separation operations.
2Ease of operation
If manual retrieval and placement of springs is performed, then flexibility is maintained, but assembly efficiency decreases and errors increase
Solution Approach 1:
The carrier is designed to be self-presenting to the assembly mechanism. The spring carrier's structure automatically positions the spring for insertion, and the magnetic retention system automatically releases the spring when triggered, reducing the need for complex manual manipulation while maintaining flexibility.
Solution Approach 2:
The manual mechanical manipulation of springs is replaced by a magnetic field-based retention and release system. The electromagnet provides automatic spring retention during conveyance and automatic release at the assembly point, increasing assembly speed while maintaining operational flexibility through programmable control.
3Device complexity
If traditional spring retention methods are used, then simplicity is maintained, but reliable retention during conveyance cannot be achieved
Solution Approach 1:
The retention mechanism uses changes in magnetic field parameters (electromagnet activation/deactivation) to control spring retention and release. This allows reliable spring retention during conveyance through magnetic attraction, with controlled release by simply changing the electrical state of the electromagnet, achieving high reliability with minimal structural complexity.
4Reliability
If production line pauses occur due to spring retrieval issues, then spring handling problems are addressed, but production time is lost
Solution Approach 1:
The spring carrier system enables continuous spring supply to the assembly line. Springs are pre-loaded onto carriers upstream and conveyed continuously to the assembly point, eliminating pauses for spring retrieval. The magnetic retention system ensures springs remain securely held during conveyance without requiring production line interruptions.
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
The spring carrier ensures secure retention and accurate extraction of coil springs, reducing manufacturing errors and production stoppages, thereby enhancing productivity and reducing costs by streamlining the handling and assembly of spring-based devices.
Implementation Method 1
the hollow body includes a magnetic member configured to magnetically attract and retain a coil spring when located within the inner cavity
Data Source
AI summary
A spring carrier for receiving, retaining, and discharging of a coil spring in a manufacturing process includes an elongate hollow body defining an inner cavity to receive the coil spring and an opening at a first proximal end of the hollow body for the insertion of the coil spring into the inner cavity and extraction of the coil spring from the inner cavity. The hollow body includes a second distal end opposite to the first proximal end. The hollow body includes a magnetic member to magnetically attract and retain the coil spring when the coil spring is located within the inner cavity.