Wire Hood Star Shaping Unit with Die Semi-Jigs
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Solution Overview
Problem
The existing methods for manufacturing wire hoods for bottle corks result in scratches, damage to the metal wire, and aesthetic issues due to the use of pliers that grip and twist the wire, leading to compromised retention and aesthetics, along with high maintenance and operational costs.
Innovation Solution
A unit for forming the star shape using a die with semi-jigs and pushers, where the metal wire is shaped into a ring and then transformed into a star by gripping units that rotate to create the stems without direct clamping, utilizing a servomotor for precise wire manipulation and shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pliers gripping heads are used to grip and twist the wire, then the wire can be shaped into the star form, but the pliers scratch the hood stems causing aesthetic problems and compromising retention
Solution Approach 1:
The patent introduces an intermediary mechanism between the gripping action and the wire. Instead of direct pliers gripping the wire, the invention uses a die with semi-jigs that guide and shape the wire through a controlled forming process. The wire is fed through the die and shaped by the geometry of the semi-jigs, eliminating direct mechanical gripping that causes scratches.
Solution Approach 2:
The patent replaces the mechanical pliers gripping system with a die-based forming system. Instead of using rotating pliers that clamp and twist the wire, the invention uses a stationary die with precisely engineered semi-jigs that guide the wire through plastic deformation to create the star shape, substituting a gripping-mechanism with a forming-mechanism.
2Ease of manufacture
If pliers are used to grip and twist the wire, then the star shape can be formed, but the galvanization is damaged leading to rust and mechanical retention problems
Solution Approach 1:
The die acts as an intermediary that enables star shape formation without direct contact between gripping surfaces and the wire. The semi-jigs within the die provide the necessary forming action through their geometry, allowing the wire to be shaped without the galvanization layer being compromised by mechanical abrasion from pliers.
3Object-affected harmful factors
If rubber rings are added to pliers to prevent scratching, then aesthetic damage is reduced, but the machine management and maintenance costs increase
Solution Approach 1:
The patent eliminates the need for protective rubber rings by replacing the pliers gripping system entirely with a die-based forming system. The semi-jigs in the die provide the necessary forming action without requiring soft protective elements, thereby simplifying the overall system and reducing maintenance needs associated with rubber ring replacement and monitoring.
4Ease of operation
If independently hinged pliers parts are used, then the gripping mechanism can open and close, but the parts may not close symmetrically causing wire slippage and execution failures
Solution Approach 1:
The patent segments the forming action into multiple controlled stages within the die. Instead of relying on a single gripping closure action, the wire is shaped through a sequence of controlled deformations as it passes through the die cavity and semi-jigs, ensuring symmetric and uniform formation without the precision issues of hinged pliers parts.
Solution Approach 2:
The wire itself serves as the guiding element through the die. The geometry of the die and semi-jigs is designed to naturally guide the wire through the forming process, with the wire's own path and flexibility ensuring symmetric engagement with the forming surfaces, eliminating the need for precisely aligned hinged gripping parts.
Data Source
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AI summary
The unit for forming the star shape of a wire hood comprises a bending device (3) to form a metal wire ring (10) and four pushers (4) which are diametrically opposed and each one spaced with a 90° angle and whose task it is to modify the ring by pushing four portions thereof towards the centre thereof to create the central part of the star shape which corresponds to the upper circular part of the hood. The bending device (3) is composed of a die constituted of two semi-jigs: a fixed negative jig (30) and a mobile positive jig (31) which, when they are coupled together, create a shaping compartment (300) for realising the metal wire ring (10) from which the star shape will be obtained. The mobile semi-jig (31) moves with a shift motion driven by air pistons to release the compartment (300). Furthermore, the pushers (4) each feature a groove (40) inside which the wire runs during the shaping of the ring so as to give continuity to the compartment (300). Finally, the unit comprises four gripping units (7) the task of each being to rotate around its own axis to wind the sections of wire in order to build the rays of the star shape which, after bending, will become the stems of the hood.