Multistage Press with Induction Heating for Adjustable Screw Lengths
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Solution Overview
Problem
Current multi-stage presses for cold forming of wire sections face challenges in efficiently producing special screws made from heat-resistant nickel-based alloys, as they require complex preheating processes and are inflexible for adjusting screw lengths, leading to inefficiencies and difficulties in producing high-quality threads.
Innovation Solution
A multi-stage press with independently controlled wire feed and heating mechanisms, utilizing an induction coil for partial heating of wire sections, allowing precise temperature control and cutting to desired lengths, enabling direct production of special screws from wire coils with adjustable lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire sections are pre-heated and formed into blanks before being fed into the multi-stage press, then special screws made from heat-resistant nickel-based alloys can be produced, but the manufacturing process becomes complex and inflexible for adjusting screw lengths
Solution Approach 1:
The patent combines the heating function and forming function into a single integrated multi-stage press system. The heating means are integrated within the press, allowing wire sections to be heated and formed in one continuous process rather than requiring separate pre-heating and forming operations. This reduces manufacturing process complexity while maintaining the ability to produce high-quality special screws from heat-resistant nickel-based alloys.
Solution Approach 2:
The patent introduces adjustable cutting means that can be positioned at different locations along the wire feed direction, enabling dynamic adjustment of screw lengths without changing the entire manufacturing process. The cutting means can be moved independently while the heating and forming operations continue, providing flexibility in producing screws of various lengths from the same heat-resistant alloy wire.
2Adaptability or versatility
If individual adjustments to screw length or dimensions are made by producing corresponding blanks first, then special screws can be manufactured, but considerable effort and time are required
Solution Approach 1:
The patent employs dynamically adjustable cutting means that can be repositioned along the wire feed direction to accommodate different screw length requirements. This dynamic adjustment capability allows rapid changes in production parameters without requiring time-consuming blank production processes, significantly reducing the time needed to adapt to different screw specifications while maintaining versatility in manufacturing various screw types from heat-resistant nickel-based alloys.
Solution Approach 2:
The heating means are positioned to pre-heat wire sections before they reach the forming stages, preparing the material in advance for immediate forming operations. This preliminary heating action eliminates the need to produce separate blanks for each screw type, as the wire can be heated on-demand and directly formed into the desired screw configuration, reducing adjustment time while maintaining adaptability.
3Temperature
If the wire section is heated before cutting to length, then partial heating for screw head formation is enabled, but coordination between heating, cutting, and forming operations becomes challenging
Solution Approach 1:
The heating means are positioned upstream of the cutting means in the wire feed direction, performing preliminary heating of the wire end section before it reaches the cutting station. This sequential arrangement allows the wire to be heated to the required temperature for screw head formation, then cut to the desired length, and finally formed in the subsequent forming stages. The independent controllability of each means ensures that the heating, cutting, and forming operations can be coordinated efficiently without excessive control system complexity.
Solution Approach 2:
The patent divides the manufacturing process into distinct functional segments: heating means for temperature control, cutting means for length adjustment, and forming means for shape creation. Each segment is independently controllable and can be optimized separately. The heating segment prepares the wire end section at a specific temperature, the cutting segment separates the heated portion to the required length, and the forming segment creates the screw head. This segmentation reduces control complexity by allowing each function to be managed independently while maintaining overall process coordination.
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
Enables efficient and flexible production of special screws by allowing precise temperature control and cutting of wire sections, improving process speed and quality, and allowing for individual adjustments in screw lengths, thus simplifying the manufacturing process.
Implementation Method 1
The means for heating a wire section include an induction coil, with the wire feed being configured for the temporary insertion of a wire section into the induction coil. This allows for the setting of a defined temperature at the end of the wire section.
Data Source
Figure 1
Figure 2a~2d
AI summary
The invention relates to a multistage press for the bulk deformation of a piece of wire, comprising a wire feed with associated apparatus for cutting to length, and a transfer device – having grippers – for receiving a piece of wire that has been cut to length and transferring the latter to subsequent forming stages, there being arranged, on that side of the cutting-to-length apparatus (3) opposite from the wire feed (2), means for partially heating a length of wire (81). The invention also relates to a method for producing a formed part with a multistage press of this type.