Remote Spring Forming Head for Direct 3D Placement
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Solution Overview
Problem
Existing spring coiling machines face challenges in efficiently transporting small, resilient springs due to their low mass and resilient nature, requiring frequent adjustments in transportation arrangements when changing spring types, shapes, lengths, or wire gauges, leading to downtime and inefficiency.
Innovation Solution
A wire shaping apparatus with a supply station and forming device that can move independently, allowing for remote control and precise placement of shaped wire components, eliminating the need for separate transportation apparatus by integrating the forming device with a robotic arm or platform for three-dimensional movement and tool control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate transportation apparatus are used to transport springs from the forming station, then the springs can be conveyed to the article, but the resilient nature and low mass of small springs cause mishandling and require frequent re-optimization when spring types change
Solution Approach 1:
The patent combines the forming device and transportation function into a single integrated system. The forming device moves independently on a conveyor belt to transport the formed spring directly to the article, eliminating the need for separate transportation apparatus and reducing mishandling of small, resilient springs.
Solution Approach 2:
The forming device is designed to perform multiple functions: it can form different types of springs and also transport them to different articles. This multi-functionality allows the same device to adapt to various spring types and article configurations without requiring separate transportation systems.
2Productivity
If the forming device is fixed relative to the supply station, then the wire can be supplied continuously, but the formed springs require separate transportation apparatus which causes mishandling and downtime
Solution Approach 1:
The forming device is made movable rather than fixed, allowing it to dynamically position itself relative to both the supply station and the article. This dynamic capability enables the forming device to transport the spring directly to the article, eliminating complex separate transportation arrangements and reducing mishandling.
3Reliability
If transportation apparatus are re-optimized for each spring type change, then proper transport can be achieved, but this process is time consuming and reduces manufacturing efficiency
Solution Approach 1:
The forming device performs the transportation function itself by moving independently on the conveyor belt, rather than relying on external transportation apparatus that would require re-optimization. This self-service capability ensures reliable spring transport without time-consuming adjustments.
Data Source
AI summary
Apparatus for forming wire components, which are in this example springs, comprises a supply station (202), for supplying spring forming material, such as metallic wire W. The supply station includes a pair of guide rollers (204) and pair of driven feed rollers (206), mounted on a heavy support plate (216). The wire is fed through a flexible sheath FS to a remotely located wire shaping device, in particular a spring forming device 208, comprising forming tools (210), a pitch control tool (212) and a cutter (214). The forming tools (210) and the pitch control tool (212) form the wire into a spring S, which is cut from the supply of wire when it is complete. The tools (210, 212) and cutter (214) are controlled remotely from a control station (220) via a bundle of flexible control cables (222), which may include a power cable. The spring forming device 208 is mounted on a positioning member (224), such as a robot arm or moveable table, configured for three-dimensional movement, and/or optionally adjustments in inclination. Without the heavy plate (216) and rollers (205, 206), the spring forming device (208) is sufficiently light in weight and compact as to be moved by the positioning member (224) to a location in which springs are to be used, thereby avoiding the need for transportation apparatus to convey the springs from the place where they are formed to the place where they are to be used.