3D Round Wire Bending With Non-Circular Grip for Rotation Control
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Solution Overview
Problem
Existing methods for processing round metallic wires into three-dimensional shapes with non-circular cross-sections for electric devices face challenges in maintaining dimensional accuracy and preventing relative rotation, often requiring additional processing steps that can compromise the wire's design specifications and bending accuracy.
Innovation Solution
A method and apparatus that linearly correct the wire, form a non-circular cross-section portion, and bend it into a predetermined three-dimensional shape using a bending machine with a wire holding portion that suppresses relative rotation, allowing for precise processing without additional shaping, and integrate a resin member for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a jig crushes a predetermined portion of a power line to a cross-section non-circular shape before resin integration, then relative rotation between the power line and resin member is suppressed, but dimensional accuracy and accuracy of form of the round metallic wire are degraded
Solution Approach 1:
The cross-section non-circular portion is formed in advance on the round metallic wire before bending and resin integration. This preliminary shaping allows the wire to be held stably during subsequent operations, preventing relative rotation while maintaining dimensional accuracy because the shaping is done on the straight wire rather than on already-bent wire with specified geometry.
2Reliability
If additional processing is performed to form a cross-section non-circular portion on a three-dimensionally shaped power line, then relative rotation is prevented, but the bending angle, bend position, and other design specifications are compromised
Solution Approach 1:
The cross-section non-circular portion is formed before the bending operation, not after. This timing is critical because forming the non-circular shape on the straight wire allows subsequent bending to achieve the desired three-dimensional shape with accurate bending angles and positions, while the non-circular portion remains available to prevent rotation during resin integration.
Solution Approach 2:
The processing steps are segmented into a specific sequence: first forming the cross-section non-circular portion on the straight wire, then performing bending to create the three-dimensional shape, and finally integrating the resin member. This segmentation ensures that each operation is performed on the wire in its most suitable state, maintaining both rotational stability and dimensional accuracy.
Data Source
AI summary
A three-dimensionally shaped round metallic wire having a cross-section non-circular portion in a predetermined portion without performing additional processing and having specified dimensional accuracy and accuracy of form. In an intermediate step in which the round metallic wire is processed in a predetermined three-dimensional shape, a cross-section non-circular portion forming machine 20 which forms the cross-section non-circular portion having a non-circular cross-sectional shape in at least one position is included. At the time of bending, the cross-section non-circular portion is held by a wire holding portion of a bending machine 30, and the bending is performed in the predetermined three-dimensional shape. Holding the cross-section non-circular portion causes relative rotation between the cross-section non-circular portion and the wire holding portion to be suppressed as compared with a case of the cross-section circular shape. Accordingly, bending accuracy in the three-dimensional shape for the round metallic wire is improved.