Magnetic Spring Transfer Belt for Coiling Machine Handling
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Solution Overview
Problem
The transfer and placement of small wire springs in manufacturing processes are challenging due to their lightweight and resilient characteristics, which can lead to mishandling and processing downtime.
Innovation Solution
A spring transfer apparatus utilizing a movable conveying substrate with magnets to attract and retain springs, allowing precise and reliable transfer from a coiling machine to a pocketing station, where the springs are inserted into discrete pockets between layers of material, supported by a flexible mandrel to prevent distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional mechanical transfer methods are used for small wire springs, then the springs can be transferred from coiling machine to pocketing station, but the lightweight and resilient characteristics cause mishandling and processing downtime
Solution Approach 1:
The patent replaces conventional mechanical transfer mechanisms with a magnetic field-based transfer system. Magnets embedded in the conveying substrate attract and hold the ferromagnetic spring material, enabling reliable transfer of lightweight springs without mechanical contact that causes mishandling. The magnetic field provides controlled attraction and release, eliminating the reliability issues associated with mechanical handling of resilient springs.
2Productivity
If magnets are used to attract springs after cutting, then the springs can be retained on the substrate, but the transfer speed and efficiency are limited
Solution Approach 1:
The patent applies magnetic attraction before the spring is cut from the spring material. The magnet on the conveying substrate attracts the formed spring while it is still connected to the spring roll, securing it in position before cutting occurs. This preliminary magnetic engagement ensures the spring is firmly held during the cutting process and subsequent transfer, maintaining positioning accuracy while enabling high-speed operation.
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 apparatus ensures efficient and precise transfer of springs, reducing the likelihood of mishandling and processing downtime, especially for smaller springs, by using a magnetic field to attract and hold springs before cutting, enabling higher transfer speeds and improved handling of densely arranged springs.
Implementation Method 1
a magnetic field of at least one of the magnets attracts the formed spring prior to being cut form a length of spring material
Implementation Method 2
at least one of the magnets being arranged to attract a spring from the coiling machine and to retain the spring on the substrate
Data Source
Figure 1
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Figure 5
AI summary
A spring transfer apparatus, shown generally at (10), is positioned adjacent a spring coiling machine (12) (shown only schematically). The transfer apparatus comprises a conveying substrate in the form of a belt (14) arranged in an endless loop and driven in a direction A by a motor (16). The belt comprises a plurality of magnetic spring holders (18) which are arranged in use to accept steel wire springs (20) from the coiling machine (12). Each of the magnetic spring holders has a pair of ferro-magnets (18a) for holding the steel springs. The magnets are arranged such that identical poles are adjacent. The apparatus is arranged such that the magnets begin to attract the formed springs before they are cut from the length of wire by the spring coiling machine.