Omnidirectional Manipulator for Spring Forming
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Solution Overview
Problem
Existing spring forming machines are limited by tools that can only move linearly and at fixed angles, making it difficult to manufacture diverse forms of springs, especially with small gauge wires, and are often too expensive for contemporary needs.
Innovation Solution
An omnidirectional manipulator is developed, comprising linear guideways and servomotors that allow tools to move in three-dimensional space, enabling them to approach and engage spring-making wires at various angles for bending, twisting, and looping operations, compatible with all existing spring forming machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If tools are mounted to the front wall board and allowed to do linear movements, then the structure is simple and cost-effective, but the tools can only approach the spring-making wire at the same angle and direction, making it impossible to suit the needs for bending and twisting or looping in all directions
Solution Approach 1:
The patent introduces a third dimension of movement by mounting the tool module on a movable platform that can translate along the Z-axis (vertical direction), while the front wall board tools move along X and Y axes. This creates three-dimensional tool positioning capability, allowing tools to approach the wire from multiple angles and directions, resolving the limitation of linear-only movement.
Solution Approach 2:
The system transitions from static tool mounting to dynamic positioning by incorporating servomotors and linear guideways that enable the tool module to move freely in three-dimensional space. The movable platform can adjust its position dynamically during operation, allowing flexible approach angles and directions for various spring forming operations.
2Adaptability or versatility
If spring forming machines are designed to rotate the wires to achieve omnidirectional operations, then all directions can be accessed, but the machines become expensive and may be incapable of performing desired operations due to small gauges of the spring-making wires
Solution Approach 1:
Instead of rotating the wire or the entire machine to achieve omnidirectional access, the patent inverts the approach by keeping the wire stationary and moving the tool module in three-dimensional space. The tool module's platform translates along Z-axis while maintaining the wire's fixed position, allowing tools to approach from any direction without rotating the delicate wire, thus avoiding damage to small-gauge wires while eliminating the need for expensive rotating mechanisms.
3Adaptability or versatility
If multiple tools are mounted to the front wall board, then various operations can be performed, but the number of tools is limited and they all move in the same linear direction, reducing versatility for diverse spring forms
Solution Approach 1:
The patent adds vertical (Z-axis) movement capability to the tool module, creating three-dimensional positioning. This allows tools to approach the wire from different heights and angles, enabling diverse spring forms to be created with the same tool set, thereby increasing versatility without requiring additional tools to be mounted on the front wall board.
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 the production of diverse spring forms by allowing tools to move freely in three dimensions, reducing damage during small-gauge spring manufacturing and eliminating the need for expensive machines, while being adaptable to all spring forming machine brands and models.
Implementation Method 1
The screw rod is rotatably mounted on the linear base and comprises a plurality of male threads. The slide seat is fit over the screw rod and comprises a plurality of female threads corresponding to and engaging with the male threads of the screw rod
Implementation Method 2
The servomotor is fixed on the linear base and is coupled to and drives the screw rod to rotate so as to drive the slide seat to do linear movement along the two rails of the linear base
Implementation Method 3
The linear base comprises two rails that are substantially parallel to each other. The guide seats are respectively corresponding to the two rails of the linear base such that the guide seats are respectively mounted on the two rails
Data Source
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AI summary
An omnidirectional manipulator is provided for use with a spring forming machine (90) and includes a tool module (14), a first linear guideway (11), a second linear guideway (12), and a third linear guideway (13). The first linear guideway (11) supports, in a manner of being mounted thereon, and drives the tool module (14) to move along a first linear axis. The second linear guideway (12) supports, in a manner of being mounted thereon, and drives the first linear guideway (11) to move along a second linear axis. The third linear guideway (13) supports, in a manner of being mounted thereon, and drives the second linear guideway (12) to move along a third linear axis. The first linear axis, the second linear axis, and the third linear axis are perpendicular to one another. Thus, when the manipulator is mounted on an existing spring forming machine (90), tools (149) that are carried on the tool module are allowed to move in a three-dimensional space to approach, at various different angles, and engage a spring-making wire extending through a hole formed in a front wall board (91) to conduct various operations at various different angles, such as bending and twisting/looping, so as to suit the needs for making diverse forms of springs.