Spring Brake Coil Manufacturing for Low-Noise Friction Contact
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Solution Overview
Problem
Existing spring brakes in home automation systems, such as those for rolling shutters and awnings, tend to generate noise due to irregular contact between the coil spring and the friction drum or hub, caused by shape defects in the spring's turns.
Innovation Solution
A method of manufacturing springs that involves separating raw turns from the ends of the intermediate portion to reduce shape defects, ensuring the spring's turns are coaxial and circular, thereby minimizing noise by improving the conformity of the spring's outer and inner contours for frictional contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the raw wire is shaped into a spiral to form the spring, then the spring can be manufactured efficiently, but form defects occur on the outermost raw coils causing noise
Solution Approach 1:
The patent extracts and removes the defective outermost raw coils from the spring structure. By separating these problematic coils (forming raw portions) from the intermediate portion that becomes the functional spring, the solution eliminates the source of form defects while preserving the manufacturing efficiency of the spiral shaping process.
Solution Approach 2:
The patent segments the continuous raw wire into distinct portions: raw portions at the ends and an intermediate portion for the spring. This segmentation allows different treatment of different sections, where the intermediate portion undergoes spiral shaping to form precise coils, while the raw portions containing defective outermost coils are separated and removed.
2Stability of the object's composition
If the spring includes outermost raw coils, then the spring structure is complete, but irregular contact with the friction drum causes noise
Solution Approach 1:
The patent removes the harmful outermost raw coils from the spring structure by separating raw portions from the intermediate portion. This extraction eliminates the irregular contact between the spring and friction drum, thereby eliminating the noise-generating defect while maintaining the structural integrity of the remaining spring coils.
3Ease of manufacture
If the spring turns are not perfectly coaxial and circular, then manufacturing is simpler, but contact irregularities with the friction element occur
Solution Approach 1:
The patent performs preliminary action by removing the defective outermost raw coils before the spring is assembled into the brake system. This preliminary removal of imperfect coils ensures that only the precisely formed intermediate coils remain, which will make proper coaxial and circular contact with the friction element during operation.
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 method produces a spring brake that is free of shape defects, reducing noise by ensuring precise circularity and conformity of the spring's turns, leading to a quieter operation.
Implementation Method 1
a friction force, by increasing or reducing an outer diameter or an inner diameter of the spring, respectively
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
The invention concerns a method for manufacturing a spring (1) for a spring brake (14), comprising a shaping and cutting step f) comprising the following sub-steps: - f1) shaping a raw wire into a coil with a plurality of raw turns, the raw wire having: raw portions that extend from the end of the raw wire over at least one raw turn, and an intermediate portion between the raw portions, - f2) separating the first raw portion and the second raw portion of the raw wire by cutting, after implementing sub-step f1), and - f3) shaping a first tab (5), at a first end of the intermediate portion, after sub-step f1), and - f4) shaping a second tab (7), at a second end of the intermediate portion opposite the first end, after sub-step f1).