Wire Bending Feedback System for Sinusoidal Spring Precision
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Solution Overview
Problem
Existing wire-bending technologies lack real-time feedback mechanisms to ensure precise control over wire shape and dimension during the bending process, leading to inefficiencies and suboptimal quality in forming sinusoidal wire structures for applications like springs.
Innovation Solution
A feedback-based system that incorporates a wire-bending mechanism with continuous oscillation, a wire-cutting mechanism, and a monitoring component using image-capturing devices and computer processors to detect deviations in wire characteristics and adjust the bending process in real-time, ensuring the sinusoidal wire structure meets selected limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional wire-bending technology is used without feedback mechanisms, then the device complexity is low, but the manufacturing precision of wire shape and dimension deteriorates
Solution Approach 1:
The patent implements a feedback-based system where a monitoring component detects characteristics of the sinusoidal wire structure and provides real-time feedback to modify the wire-bending process. This closed-loop control ensures manufacturing precision by continuously adjusting the bending parameters based on actual wire characteristics, resolving the contradiction between low device complexity and poor manufacturing precision.
2Manufacturing precision
If real-time feedback monitoring is implemented, then the manufacturing precision improves, but the device complexity increases
Solution Approach 1:
The monitoring component detects wire characteristics and provides feedback to modify the bending process in real-time, improving manufacturing precision through closed-loop control
Solution Approach 2:
The system automatically adjusts the wire-bending process based on feedback from the monitoring component without requiring external intervention, allowing the system to self-correct and maintain precision while reducing operational complexity
3Productivity
If continuous oscillation wire-bending is used, then the productivity increases, but the manufacturing precision of sinusoidal wire structure deteriorates
Solution Approach 1:
The feedback-based system monitors wire characteristics during continuous oscillation bending and provides real-time modifications to maintain sinusoidal structure quality, enabling high-speed production without sacrificing precision
Solution Approach 2:
The wire-bending element operates with continuous oscillation to maintain constant contact with the wire, enabling uninterrupted high-speed production while the feedback system ensures quality standards are met throughout the continuous process
4Manufacturing precision
If feedback-based real-time modification is implemented, then the manufacturing precision and quality improve, but the device complexity and setup time increase
Solution Approach 1:
The system automatically adjusts bending parameters based on feedback from the monitoring component, enabling self-correction and reducing the need for manual setup and intervention, thereby minimizing setup time while maintaining high precision
Data Source
AI summary
Feedback-based systems and methods for bending wire are provided. The systems and methods may allow for modification of wire bending based on feedback received from one or more feedback-generating elements (e.g., image-capturing device(s), computer processing device(s), vision systems, etc.) used for monitoring one or more characteristics of a wire (e.g., shape, size, dimension, angular configuration, etc.) to determine, and provide to various wire-bending components of the system, appropriate modifications to the wire-bending process. Modifications to the wire-bending process may occur in real time without stopping the wire-bending process. Furthermore, a wire may be bent into a sinusoidal wire structure for forming springs for use in various applications.