Vision-Based Spring Machine Monitoring for Coil Dimension Control
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Solution Overview
Problem
The high-speed production process of coil springs in spring machines can result in slight disturbances causing the diameter or pitch of produced coil springs to exceed tolerance, affecting the quality of the coil springs.
Innovation Solution
A monitoring system for spring machines that includes a carrier platform, a sensing module with a vision sensor and processing unit, and a processing device connected to a database of correction values. The system detects deviations in coil dimensions, generates a detection signal, and transmits correction values to the spring machine to adjust the coil dimensions in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed production is used to increase productivity, then the production speed increases, but the dimensional accuracy of coil springs deteriorates due to disturbances exceeding tolerance
Solution Approach 1:
The patent implements a closed-loop feedback control system where a vision sensor continuously monitors the actual dimensions of coil springs during high-speed production. The controller compares measured dimensions with target values and automatically adjusts process parameters (such as wire feeding speed, coiling speed, or tool positioning) to compensate for deviations. This real-time feedback mechanism enables maintaining dimensional accuracy even at high production speeds by dynamically correcting disturbances as they occur.
Solution Approach 2:
The patent replaces traditional mechanical measurement and control systems with optical sensing and automated control. Instead of using mechanical gauges or manual inspection methods that cannot keep up with high-speed production, the system employs vision sensors (optical systems) to non-contactively measure coil spring dimensions in real-time. This substitution enables accurate measurement and control at high speeds without the inertia and response delays inherent in mechanical systems.
2Device complexity
If traditional monitoring methods are used, then the system complexity remains low, but the ability to detect and correct dimensional deviations in real-time is insufficient
Solution Approach 1:
The patent implements a self-correcting system where the monitoring and control functions are integrated into the production line. The vision sensor automatically detects dimensional deviations, the controller processes the data and determines necessary corrections, and the system automatically adjusts process parameters without requiring external intervention. This self-service capability enhances quality control reliability while keeping the system architecture relatively simple and intuitive.
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 monitoring system effectively maintains the dimensional accuracy of coil springs by allowing real-time adjustments based on detected deviations, thereby improving the quality and consistency of coil spring production.
Implementation Method 1
The vision sensor is configured to perform image detection on a dimension of a coil of a coil spring that is to be produced by the spring machine
Data Source
AI summary
A monitoring system for a spring machine includes a carrier platform, a sensing module, and a processing device. The carrier platform is adapted to be movably disposed adjacent to the spring machine. The sensing module includes a vision sensor, and a processing unit that is connected to the vision sensor. The vision sensor is configured to perform image detection on a dimension of a coil of a coil spring to be produced by the spring machine, and to generate and output a detection result of the dimension. The processing unit is configured to generate a detection signal according to the detection result received from the vision sensor. The processing device stores multiple correction values, and is configured to, obtain according to the detection signal, and to transmit to the spring machine, one of the correction values, for the spring machine to adjust the dimension of a coil later formed.