Multi-Strand Wire Feeder for Coil Spring Manufacturing
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Solution Overview
Problem
Conventional coiler machines are unable to manufacture multi-strand coils, which are necessary for advanced inner spring cores in mattresses, due to the torsional torque that can cause the multi-strand wire to fray or fracture during the coil-winding process.
Innovation Solution
The system includes a feeder spool assembly that allows for additional rotational freedom, specifically rotating about a second axis orthogonal to the primary axis, to accommodate torsional torque and prevent damage, along with optional features like torque sensors, motor controllers, magnetic-particle clutches, and brakes to manage wire rotation and tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional coiler machines are used to manufacture multi-strand coils, then the manufacturing process can be simplified, but the multi-strand wire will suffer from torsional torque causing it to fray or fracture
Solution Approach 1:
The wire holder is designed to rotate dynamically about a second axis orthogonal to the primary spool axis, allowing the system to adapt to torsional torque forces during the coil-winding process. This dynamic rotation capability enables the wire holder to accommodate the multi-strand wire's twisting tendencies while maintaining continuous feeding, thus preventing wire fraying or fracture without complicating the manufacturing process
2Reliability
If the wire holder rotates about a second axis orthogonal to the spool axis, then torsional torque buildup is prevented, but the device complexity increases
Solution Approach 1:
The wire holder combines multiple functions into a single integrated component: it holds the wire spool, allows rotation about the primary axis for wire dispensing, and simultaneously enables rotation about the second orthogonal axis to accommodate torsional torque. This merging of functions prevents the need for separate torque compensation mechanisms, thereby reducing overall device complexity while maintaining wire integrity
3Reliability
If additional rotational freedom is provided to the wire holder, then multi-strand wire can be processed without damage, but the manufacturing precision may be compromised
Solution Approach 1:
The system incorporates feedback mechanisms that monitor the wire holder's rotational position and the coil spring formation process. This feedback allows the control system to adjust the rotation about the second axis in real-time, ensuring that the additional rotational freedom does not compromise the precision of coil spring dimensions while still preventing wire damage
Data Source
AI summary
The systems and methods include a feed mechanism supplying multi-strand wire to a coil-spring winder. The coil spring typically has a plurality of turns and is resilient. The multi-strand wire is typically steel, but may be of other suitable material, or a combination of materials. The coil-spring winder receives wire from a spool of wire and forms that wire into a coil spring. Typically, but not always, the coil-spring winder cuts the coil spring to a desired length, and thereby forms a plurality of coil springs of the type that can be employed in mattresses, furniture, car seats, for industrial machines, or for any other application. To feed the coil-spring winder, the systems include a wire holder that supplies the wire to the coil-spring winder along a feed direction. The wire holder is supported for rotation about an axis that may be aligned with the feed direction. The rotation of the wire holder may be substantially synchronous with the formation of the turns of the coil spring. In one embodiment, the spool of wire is mounted onto a wire holder rotatable about a holding axis for reducing torque about a cross section of the wire. Thus, as the spool of wire revolves around the central spool axis, the spool also revolves around a second axis, which typically is orthogonal to the spool axis. In this way, it is understood that the coil-spring winder can pull wire off the spool without it causing twisting that may unravel or snap the multi-strand wire.