Spring Winding Machine Setup Using 3D Model-Based Measurement
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Solution Overview
Problem
Conventional spring coiling machines require significant operator expertise and time for setup and re-setup, leading to inefficiencies in producing coil springs within tight geometric tolerances, as changes in tool positions and travel paths are often determined through trial-and-error, and direct spring measurements are imprecise or costly.
Innovation Solution
A method and machine that utilize a three-dimensional spring model and camera-based measurement to automate the setup process, allowing for model-based spring measurement and correction of production parameters, enabling rapid and accurate production of coil springs within narrow tolerances by comparing a mathematical spring model with actual coil spring images.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional spring coiling machines are used with manual setup procedures, then operator control over production parameters is maintained, but setup time and required operator expertise increase significantly
Solution Approach 1:
The patent creates a three-dimensional computer model that copies and represents the physical spring geometry and machine setup parameters. This digital model allows operators to define and store setup configurations virtually, eliminating the need for manual physical adjustment and reducing setup time while maintaining control.
Solution Approach 2:
The system performs preliminary calculations and simulations using the three-dimensional model before actual production begins. Travel paths, tool positions, and production parameters are pre-determined through computer-based modeling, allowing operators to avoid time-consuming trial-and-error adjustments during setup.
2Adaptability or versatility
If trial-and-error methods are used to determine tool positions and travel paths, then flexibility in adjusting parameters is maintained, but production time and number of springs produced decrease
Solution Approach 1:
The system incorporates feedback mechanisms where measurement data from actual springs is compared against the three-dimensional model. Deviations are automatically calculated and used to adjust the model and production parameters, maintaining adaptability while eliminating trial-and-error methods and increasing productivity.
Solution Approach 2:
The patent replaces manual mechanical adjustment processes with computer-based calculations and automated control. The three-dimensional model enables virtual simulation and optimization of tool paths and positions, substituting physical trial-and-error with digital computation to maintain flexibility while dramatically increasing output.
3Measurement precision
If central measuring devices are used for spring measurement, then measurement capability is provided, but operator time and measurement accuracy may be compromised due to operator travel and setup
Solution Approach 1:
The three-dimensional computer model serves as an intermediary between the physical spring and the measurement process. Instead of directly measuring physical springs and requiring operator intervention, the system uses the digital model to represent and analyze spring geometry, improving both precision and efficiency.
Solution Approach 2:
The system creates digital copies of springs through scanning or modeling, allowing measurements to be performed on the digital representation rather than the physical object. This eliminates the need for operators to physically handle and measure each spring, improving accuracy while reducing measurement time.
Data Source
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AI summary
The invention relates to a method for producing coil springs by spring winding by means of a numerically controlled spring winding machine, in which a wire is fed by a feeding device of a forming device of the spring winding machine under the control of an NC control program and is formed into a coil spring by means of tools of the forming device. According to the invention, a desired target geometry of the coil spring and an NC control program suitable for producing the target geometry are defined. Furthermore, a three-dimensional spring model of the coil spring is established using model parameters, wherein the spring model represents the desired target geometry. At least one two-dimensional measurement image of a spring portion of the coil spring is acquired by means of a camera. A 2D reference image is derived from a spring portion of the spring model, which spring portion corresponds to the spring portion of the measurement image. Said 2D reference image is compared with the measurement image of the spring portion for determining at least one deviation variable. Optionally, the spring model is modified by changing at least one model parameter in the way that a deviation defined by the deviation variable between the 2D reference image and the measurement image of the spring portion is minimized, whereby a modified spring model is established. At least one measurement value describing the actual geometry of the coil spring is derived from the spring model. Said measurement value is processed.