Rotary Coil Spring Cutting for Continuous Wire Feeding
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Solution Overview
Problem
Existing methods for producing coil springs from continuously fed wire require complex cutting mechanisms, which complicates the process and may lead to inefficiencies in cutting wire without stopping or slowing the feeding speed.
Innovation Solution
A mechanism featuring a rotary cutter with a rotating blade that cuts the deformed wire at a constant speed, assisted by adjustable mandrel and bending tools, allowing for efficient cutting without complex structures, and a transport mechanism using magnetic carriers for reliable coil spring transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a reciprocating cutting blade is used to cut continuously fed wire, then cutting can be performed without stopping the wire feed, but the cutting mechanism becomes complex
Solution Approach 1:
Instead of moving the cutting blade in a reciprocating motion to cut the wire, the invention inverts the approach by rotating the wire itself past a stationary cutting blade. The wire is fed through a rotating mechanism that brings it into contact with the blade at the appropriate position, eliminating the need for complex reciprocating blade guidance while maintaining continuous cutting capability
Solution Approach 2:
The invention replaces the mechanical reciprocating cutting system with a rotational feeding system combined with a stationary blade. The rotational mechanism controls wire delivery and positioning, substituting the complex reciprocating blade guidance with a simpler rotational drive that achieves the same continuous cutting function
2Manufacturing precision
If the wire feeding speed is stopped or slowed for cutting, then cutting precision can be improved, but production efficiency decreases
Solution Approach 1:
The invention maintains continuous wire feeding at constant speed throughout the cutting process. The rotational mechanism ensures that the wire is continuously delivered and positioned past the stationary blade without interruption or speed reduction, allowing both high precision cutting and continuous production to occur simultaneously
Solution Approach 2:
The rotational feeding mechanism preliminarily positions and guides the wire into the correct orientation and location before it reaches the cutting blade. This pre-positioning action ensures that cutting precision is achieved through proper wire alignment rather than through speed reduction or stopping
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 production of coil springs with precise cutting and reliable transfer, maintaining constant wire feeding speed and adapting to various wire gauges and geometries, thus simplifying the production process and improving output quality.
Implementation Method 1
The transport mechanism may comprise at least one magnetic carrier for engaging with the deformed wire and moving the coil spring from the winding stage
Data Source
Figure 1A
Figure 1B~1C
Figure 2
AI summary
A mechanism for producing coil springs (10) includes a winding stage (110) for engaging with a wire (20) and deforming the wire (20) to coil windings as the wire (20) moves through the winding stage (110). Further, the mechanism comprises a feed mechanism (120) configured to feed the wire (20) to the winding stage (110). Further, the mechanism comprises a rotary cutter (130). The rotary cutter (130) is configured to cut the deformed wire (20) into portions forming separate coil springs (10) and a blade (135) which is driven for rotation about a stationary rotation axis.