Continuous Feed Spring Steel Strip Bending with Synchronized NC Cutting
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Solution Overview
Problem
Existing methods for manufacturing bent spring elements, such as windshield wiper support elements, face issues with intermittent feed and varying speeds, leading to component wear and inaccuracies, especially when producing large quantities, and require trigger holes for process control which can cause length and bending inaccuracies.
Innovation Solution
A continuous feed system with numerically controlled cutting tools synchronized with the feed movement of the spring steel strip, adjustable cutting tools, and a pre-bending unit to maintain consistent inlet conditions, along with precise adjustment of bending rollers and guide rollers, ensures uniform bending and reduces wear by maintaining consistent feed speed and eliminating the need for trigger holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If an intermittent feed system with start-stop operation is used, then large numbers of items can be produced per unit of time, but component wear increases and feed speed varies greatly with accelerations
Solution Approach 1:
The patent implements continuous feed movement of the spring steel strip through the bending unit without start-stop operations. The cutting tools are synchronized with the continuous feed, eliminating the intermittent operation that causes component wear while maintaining high productivity through efficient continuous processing.
2Ease of operation
If trigger holes are used to control the process, then feed positioning is achieved, but length and bending inaccuracies occur
Solution Approach 1:
The patent eliminates trigger holes from the process by using a trigger-hole-free control method. The cutting tools are synchronized with the continuous feed movement through numerical control, achieving both easy process control and high bending accuracy without the need for trigger holes that cause length and bending inaccuracies.
3Measurement precision
If cutting tools are stationary relative to the housing, then adjustment precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical adjustment mechanisms with a numerical control system that synchronizes cutting tool movement with feed movement. The cutting tools are adjustable in the longitudinal direction through NC control, eliminating the need for complex mechanical positioning systems while achieving high positioning accuracy.
Data Source
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AI summary
The invention is based on a method of producing bent spring elements from a spring steel strip (14), wherein a feed unit (16) delivers the spring steel strip (14) from a supply roll (12) to a bending unit (32) having at least three bending rollers (34) and a reverse bending roller (36), of which at least one bending roller (34) and the reverse bending roller (36) can be adjusted transversely to the spring steel strip (14) by bending motors (60, 62), and wherein a cutting-off unit (44) adjoins the bending unit (32), said cutting-off unit (44) cutting off the spring steel strip (14) into individual spring elements by means of cutting-off tools (46, 48; 76, 78). It is proposed that the cutting-off tools (46, 48; 76, 78) be movable in the longitudinal direction of the spring steel strip (14) in a numerically controlled manner and that they be synchronized with the feed movement of the spring steel strip (14) during the cutting-off operation.