Multistage Press With Induction Heating for Variable-Length Screw Forming
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Solution Overview
Problem
Existing multi-stage presses for cold forming of wire sections face challenges in producing special screws made from heat-resistant nickel-based alloys, as they require pre-heating of screw head regions and are inefficient for adjusting screw lengths, leading to complex and labor-intensive processes.
Innovation Solution
A multi-stage press with independent control of wire feed and cutting mechanisms, incorporating an induction coil for partial heating and servo-drive for precise wire movement, allows direct production of special screws from a wire coil by heating and cutting the wire section to a desired length before forming, enabling simultaneous heating and forming across stages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-heating of screw head regions is performed before forming, then heat-resistant nickel-based alloys can be formed, but the production process becomes very complicated and labor-intensive
Solution Approach 1:
The induction coil performs preliminary heating of the wire end section before the forming process begins. This allows the material to be softened in advance, making it easier to form heat-resistant alloys without requiring complex post-heating arrangements or manual intervention.
Solution Approach 2:
The patent replaces manual or mechanical heating methods with an induction heating system that uses electromagnetic fields to heat the wire end section. This substitution automates the heating process and eliminates the need for complex mechanical heating devices or manual operation.
2Adaptability or versatility
If individual switching of screw length or dimension is enabled, then product variety increases, but blanks must be produced separately for each specification
Solution Approach 1:
The patent introduces dynamic control capabilities where the wire feed speed, cutting position, and induction coil activation can be adjusted in real-time based on the desired screw specifications. This dynamic adjustment allows different screw lengths and dimensions to be produced without changing the basic setup or producing separate blanks for each specification.
Solution Approach 2:
The system enables parameter changes in wire feed rate, cutting length, and heating duration to produce different screw specifications. By varying these parameters, the same equipment can adapt to different product requirements without requiring separate blank production or complex reconfiguration.
3Productivity
If six wire sections are formed at every advancement of the cylinder, then high process speed is achieved, but special materials require additional heating steps
Solution Approach 1:
The induction coil performs preliminary heating of the wire end section before the forming process begins. This allows the material to be softened in advance, making it easier to form heat-resistant alloys without requiring complex post-heating arrangements or manual intervention.
Solution Approach 2:
The patent maintains continuous production by integrating the induction heating process into the existing multi-stage press cycle. The heating occurs during the wire feed phase, and the heated section is immediately formed in subsequent stages, ensuring continuous operation without interrupting the high-speed production cycle.
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 enables efficient and precise production of special screws with adjustable lengths by allowing partial heating and cutting of wire sections, improving process speed and reducing complexity in handling heat-resistant materials.
Implementation Method 1
the means for heating a wire section comprise an induction coil, wherein the wire feed is set up for temporary introduction of a wire section into the induction coil
Data Source
AI summary
A multistage press for the bulk deformation of a piece of wire includes 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 opposite from the wire feed, a device for partially heating a length of wire. A method produces a formed part with a multistage press of this type.