Spring Core Section Arrangement via Conveyor Speed Feedback
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Solution Overview
Problem
Existing methods for arranging sections of a coil of springs to produce a spring core require complex conveyor systems and multiple sensors to ensure the predetermined length and regular spacing of spring pockets, which increases operational effort and complexity.
Innovation Solution
A method utilizing feedback control to set relative conveying speeds between two conveyors based on measurements taken on the second conveyor, eliminating the need for sensors on the first conveyor and allowing for direct regulation of segment lengths to achieve the predetermined length and spacing of spring pockets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sensors are placed on both the first conveyor and second conveyor to detect spring coil segments, then the length control precision is improved, but the device complexity and operational effort increase
Solution Approach 1:
The patent removes the sensor from the first conveyor, keeping only the sensor on the second conveyor. This extraction eliminates unnecessary measurement points while maintaining sufficient control precision through the remaining sensor combined with relative conveying speed adjustment.
Solution Approach 2:
The patent implements feedback control where the sensor on the second conveyor detects actual segment lengths, and the control unit adjusts the relative conveying speeds of the two conveyors based on this feedback to achieve the specified segment length.
2Measurement precision
If multiple sensors are used to detect segment lengths on the first conveyor, then the measurement precision is improved, but the operational effort and device complexity increase
Solution Approach 1:
The patent extracts and removes the sensor from the first conveyor, reducing the number of sensors from multiple to just one on the second conveyor, thereby simplifying operation while maintaining measurement capability.
Solution Approach 2:
The patent uses the relative conveying speed between the two conveyors as an intermediary mechanism to achieve length control, replacing the need for direct measurement and adjustment on the first conveyor with a simpler single-point measurement and speed-based control system.
3Reliability
If the first conveyor is made longer to accommodate full section conveyance, then the conveying reliability is improved, but the device complexity and space requirements increase
Solution Approach 1:
The patent introduces dynamic relative conveying speeds between the first and second conveyors, allowing the system to adapt to varying segment lengths and maintain reliable conveying without requiring a longer fixed conveyor configuration.
Data Source
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AI summary
To arrange sections (6) of a spring coil (3), comprising a predetermined number of spring pockets (13), for the production of a spring core (9), each section (6) is conveyed by a first conveyor (4), transferred to a second conveyor (7), and conveyed further by the second conveyor (7). During this process, the lengths of segments of each section (6) are measured in the area of the second conveyor (7), and, in order to set a predetermined length of the section (6) on the second conveyor (7), the relative conveying speeds of the second conveyor (7) with respect to the first conveyor (4) are adjusted depending on the measured lengths, while both conveyors (4, 7) convey the respective section (6).