Rotary Wire Forming Table for Stable Small-Diameter Shaping
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Solution Overview
Problem
Conventional wire forming apparatuses face instability in product shape due to wire slippage and curving tendencies during rotation, especially with smaller wire diameters, and existing solutions complicate tool positioning and productivity.
Innovation Solution
A wire forming apparatus with a rotary table that can rotate and slide tools independently, using a simple driving mechanism, allowing for flexible tool arrangement and elimination of the need to rotate the wire around its axis, featuring a table driving mechanism, tool slide mechanism, and tool rotation mechanism to transmit driving forces efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a pair of feed rollers is used to rotate the wire around the wire axis, then the wire can be processed into a final product shape, but the wire develops a curving tendency with large curvature that causes the wire to bend in a winding direction, affecting the final product shape
Solution Approach 1:
Instead of rotating the wire around its axis using feed rollers, the invention inverts the approach by keeping the wire stationary and rotating the tools around the wire axis. This eliminates the curving tendency caused by wire rotation while still enabling the wire to be processed into the desired final product shape through tool rotation and movement.
Solution Approach 2:
The invention introduces a rotary table as an intermediary mechanism that holds multiple tools and rotates them around the wire axis. This mediator enables the wire processing function without requiring the wire itself to rotate, thereby eliminating the harmful curving effect while maintaining the ability to create complex shapes.
2Ease of operation
If feed rollers hold the wire from opposite sides with pressure during wire rotation, then the wire can be rotated, but repeated rotation over a long period of time causes slight slippage between the feed rollers and the wire, leading to instability in the product shape
Solution Approach 1:
The invention extracts the rotation function from the feed rollers and transfers it to a dedicated rotary table mechanism. By removing the wire rotation task from the feed rollers, slippage is eliminated and the feed rollers can focus solely on feeding the wire, thereby improving both operation ease and product shape stability.
3Productivity
If the wire is twisted between the wire supply mechanism and the feed rollers during wire rotation, then the wire can be fed and rotated, but the twisting effect cannot be completely eliminated and becomes more significant as the wire diameter is smaller, affecting product shape stability
Solution Approach 1:
The invention inverts the rotation approach by keeping the wire straight and stationary while rotating the tools around it. This eliminates the twisting effect between the wire supply mechanism and feed rollers, as the wire no longer needs to rotate, thereby improving manufacturing precision especially for small diameter wires.
4Adaptability or versatility
If multiple driving mechanisms are arranged on the forming table to enable tools to be driven regardless of the rotational position of the rotary table, then the tools can always be driven, but the device complexity increases
Solution Approach 1:
The invention creates a universal driving system where a single driving mechanism on the rotary table can drive all tools regardless of their rotational position. The rotary table itself serves as a multi-functional platform that combines tool holding, rotation, and driving functions, eliminating the need for multiple separate driving mechanisms.
5Adaptability or versatility
If a two-dimensional table is moved in XY direction to change the positions of slide tools and perform sliding operation, then the tools can be positioned and slid, but it is difficult to rapidly move the heavy two-dimensional table, affecting productivity improvement
Solution Approach 1:
The invention segments the positioning and sliding functions from the heavy two-dimensional table movement. Instead of moving the entire heavy table for positioning, the rotary table rotates to position tools, and individual slide mechanisms handle sliding operations. This segmentation enables rapid positioning through light rotary movement rather than heavy linear table movement.
Data Source
AI summary
A wire forming apparatus 1 comprises a rotary table 22 that is rotatably supported by a table body 21, a slide tool unit 100A that is attached to the rotary table 22 and supports a slide tool T1 capable of sliding toward a wire guide, and a tool slide mechanism 60 that is supported by the table body 21 and transmits a driving force for sliding the slide tool T1 to the slide tool unit 100A. The tool slide mechanism 60 has a single motive power transmission member 61 that is rotatably supported by the table body 21, and a driving force generated by a rotation of the motive power transmission member 61 is transmitted, in common, to a plurality of slide tools T1 attached to the rotary table 22.