Rotating Wheel Wire Forming for Dual-End Cold Machining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing machining machines for wire-like materials, particularly in cold press-forming, face challenges such as the inability to efficiently shape both ends of wire sections without forming undercuts, leading to complex and costly designs with large dimensions, making them difficult to install and operate in limited spaces.
Innovation Solution
A compact cold press-forming machine with a vertically extending frame and a rotating wheel that allows for simultaneous machining of both ends of wire sections using top and bottom machining heads with cam-actuated kinematic transmissions, enabling efficient upsetting and extrusion operations in a small footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional forming/bending machines are used to cold-work wire sections, then the wire ends can be deformed, but undercuts are formed that prevent extraction by linear displacement, requiring complex opening devices that increase cost and weaken support structure
Solution Approach 1:
The patent inverts the conventional approach by using a rotating wheel with vertically oriented wire sections instead of linear displacement. The wire is held vertically between top and bottom machining heads, and the wheel rotation enables extraction through rotational movement rather than linear displacement, eliminating the need for complex opening devices.
Solution Approach 2:
The patent changes the extraction dimension from linear (conventional) to rotational (vertical axis). By orienting wire sections vertically and using wheel rotation about a vertical axis, the extraction movement occurs in a different dimensional mode, avoiding undercut formation and eliminating the need for complex opening mechanisms.
2Stability of the object's composition
If large and complex presses are used to machine long and thin workpieces, then the workpieces can be kept straight, but the machine dimensions become very large requiring very large installation spaces
Solution Approach 1:
The patent reorients the machining process from horizontal to vertical by standing the wire sections vertically between top and bottom machining heads. This dimensional change allows compact machine dimensions while maintaining workpiece stability through vertical support, eliminating the need for large horizontal presses.
Solution Approach 2:
The patent uses a rotating wheel to dynamically position and support wire sections during machining. The rotation about a vertical axis provides continuous support and stability to long and thin workpieces while enabling compact machine design, replacing static large presses with a dynamic rotating system.
3Manufacturing precision
If conventional machines machine both ends of wire sections, then complete machining is achieved, but the process is inefficient and requires complex positioning
Solution Approach 1:
The patent enables continuous machining of both wire ends through wheel rotation. As the wheel rotates, different sections of wire pass between top and bottom machining heads, allowing both ends to be machined in sequence without stopping or repositioning the workpiece, significantly improving productivity.
Solution Approach 2:
The patent makes the machining system universal by using the same top and bottom machining heads for both ends of the wire. The rotating wheel presents different wire sections to the same machining apparatus, eliminating the need for separate positioning mechanisms and enabling efficient dual-end machining.
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
The machine achieves efficient machining of wire-like materials with reduced dimensions, allowing for easy installation and operation in small spaces, while enabling simultaneous machining of both ends without undercuts, thus reducing costs and increasing robustness.
Implementation Method 1
cam mechanisms, designed to actuate the gripping means and the machining heads in the vertical direction
Implementation Method 2
A wheel lying in a horizontal plane and arranged to rotate about a vertical axis... for rotating it between a horizontally oriented position for transporting the section of wire and a vertically oriented position for the machining
Implementation Method 3
machine for machining, in particular press-forming, wire-like material... each suitable for machining, in particular for upsetting or extruding, a respective section of wire-like material
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Machine for machining, in particular press-forming, wire-like material (1, 1a), comprising: a vertically extending frame comprising two half-frames (10,20) arranged opposite each other in the vertical direction (Z-Z), so as to form an interspace (102), the frame having, connected thereto, at least a first machining unit (100) and a second machining unit (200), each suitable for machining, in particular for upsetting or extruding, a respective section (1b, 1c) of wire-like material (1a), said units each comprising a top machining head (110,210) and a bottom machining head (210,220) situated opposite each other in the vertical direction (Z-Z) and arranged on opposite sides of the interspace (1020); a wheel (400) lying in a horizontal plane (X-Y), rotating about a vertical axis (Z-Z) and housed inside the said interspace (1020); wherein the wheel (400) carries devices for gripping a section of wire (1b) and for rotating it between a horizontally oriented position for transporting the section of wire (1b) and a vertically oriented position for the machining of at least one of the opposite ends of the said section of wire (1b) by one of said machining units.