Spring Manufacturing Line with Quick-Change Formation Devices
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Solution Overview
Problem
The existing spring manufacturing lines require laborious and time-consuming operations to switch between different stabilizer shapes due to the need to detach and reposition formation units, which is exacerbated when producing multiple types of stabilizers on a single line.
Innovation Solution
A spring product manufacturing line that includes a device transport line to move formation devices with their base mounts between a manufacturing area and a device switching area, allowing for quick switching of formation devices without the need to remove them from the base mount or detach pressure fluid lines at the manufacturing area, utilizing a car and rail system to facilitate efficient device replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If formation units are detached from the stand and moved to a reserve stand by crane when switching stabilizer shapes, then different stabilizer shapes can be manufactured, but the switching operation becomes laborious and time-consuming
Solution Approach 1:
A reserve stand is prepared in advance with a formation unit ready for installation. The pressure fluid line is pre-connected to the reserve stand, so when switching is needed, the formation unit can be quickly installed without having to connect hydraulic lines during the switching operation itself.
Solution Approach 2:
The system is divided into a manufacturing stand and a reserve stand, allowing independent preparation and quick swapping. The formation units are segmented as replaceable modules that can be independently installed or removed without affecting the entire system.
2Adaptability or versatility
If formation units are detached from the stand and moved by crane when switching stabilizer shapes, then different stabilizer shapes can be manufactured, but the operation requires significant labor
Solution Approach 1:
The reserve stand is prepared in advance with the formation unit and pressure fluid line connection already in place. This preliminary preparation eliminates the need for complex manual operations during the actual switching process, reducing labor requirements.
Solution Approach 2:
The reserve stand acts as an intermediary that holds the replacement formation unit ready. Instead of directly moving units between manufacturing positions, the reserve stand serves as a buffer that simplifies the switching operation to a simple installation process.
3Adaptability or versatility
If multiple types of stabilizers are manufactured on a single line with frequent switching, then production flexibility is improved, but the laborious switching operation becomes a serious problem
Solution Approach 1:
By preparing the reserve stand in advance with the next formation unit ready and pre-connected pressure fluid lines, the system enables rapid switching between stabilizer types. This eliminates the time-consuming operations that would otherwise reduce productivity during frequent model changes.
Solution Approach 2:
The system transitions from a static configuration to a dynamic switching system where formation units can be quickly replaced. The reserve stand mechanism provides the dynamic capability to adapt the production line to different stabilizer types without disrupting overall productivity.
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
Enables rapid switching of formation devices within a short time frame, reducing operational complexity and labor, and allowing for efficient production of various stabilizer types on a single line by streamlining the device switching process.
Implementation Method 1
a pressure fluid line that supplies pressure fluid to the respective formation units provided at the formation device
Implementation Method 2
a formation device which bends a spring material into a predetermined shape; a plurality of formation units that perform a hydraulic bending process on the spring material
Data Source
AI summary
The invention provides a spring product manufacturing line comprising: a manufacturing area 2 at which a formation device 50 attached to a base mount 52 plastically processes a spring material into a spring product; a formation device switching area 3 at which one formation device 50 is removed from the mount 52 and switched with another forming device 50; and a formation device transport line 4 that conveys a formation device 50 attached to a base mount 52 at the device switching area 3 to a manufacturing area 2; wherein the formation device 50 is provided with a plurality of formation units 54 that perform a bending process on the spring material by fluid pressure; the base mount 52 is provided with a pressure fluid line 62 that supplies pressure fluid to the formation units 54 provided at the formation device 50, and that is removably connected to each of the formation units 54; and the attachment or removal of the pressure fluid line 62 with respect to the formation device 50 is performed at the device switching area 3.