Worm Gear Torsion Spring Winding for Safer High-Torque Installation
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Solution Overview
Problem
The existing methods for winding and unwinding torsion springs are hazardous and physically demanding, as they require high torque and manual labor, leading to risks of injury and damage during installation and removal, with existing tools having multiple components that increase the risk of missteps and accidents.
Innovation Solution
A spring winding apparatus featuring a base with a handle and head, including a worm gear and ring gear mechanism that rotates the torsion spring for safe and efficient winding and unwinding, using a drill or other tool to couple with the worm gear for reduced manual effort and increased safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual winding of torsion springs is performed, then the spring can be wound or unwound, but high physical effort and risk of injury occur due to high torque requirements
Solution Approach 1:
The patent introduces a winding apparatus with a handle, shaft, and gear mechanism that acts as an intermediary between the user and the torsion spring. This intermediary device transfers and amplifies the user's rotational input into the high-torque output needed to wind the spring, eliminating the need for direct manual handling of the spring ends and thereby reducing injury risk while maintaining ease of operation
2Ease of operation
If existing multi-component tools are used to wind springs, then some mechanical advantage is provided, but the risk of slipping and missteps increases due to multiple moving components
Solution Approach 1:
The patent merges multiple previously separate components (handle, shaft, gears, and spring-contact elements) into a single integrated winding apparatus. This unified structure eliminates interfaces between separate parts where slipping could occur, while maintaining the mechanical advantage needed to wind high-torque torsion springs safely and reliably
3Productivity
If torsion springs are wound or unwound manually, then the spring energy can be stored or released, but the task is physically taxing due to repetitive motion and high torque
Solution Approach 1:
The patent replaces the direct manual mechanical system (user applying torque directly to spring ends) with a mechanical advantage system featuring a handle, shaft, and gear mechanism. This substitution allows the user to apply much lower forces through larger rotational movements, dramatically reducing physical taxation while maintaining or improving productivity in spring installation and removal tasks
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
The apparatus allows for safe and efficient installation and removal of torsion springs with reduced physical effort and risk of injury, mitigating the dangers associated with high stored mechanical energy and repetitive motion.
Implementation Method 1
A worm gear is disposed on the base between the handle and the head. A ring gear is disposed proximate to a front side of the base, with the ring gear being in mechanical communication with the worm gear.
Implementation Method 2
On a garage door, a torsion spring stores energy when wound, with that energy being transferred to cables attached to the spring and to the bottom of a garage door
Data Source
AI summary
A tool assembly designed to couple to a torsion spring and torsion rod to wind and unwind the torsion spring on the torsion rod. The tool assembly includes a variety of components in mechanical communication with one other to rotate the torsion spring. Specifically, the assembly includes a worm gear in mechanical communication with a ring gear and a set of brackets securable to a torsion spring. Between the ring gear and the brackets are a series of plates arranged and assembled on a base, providing a singular device within the assembly that a user can grip to manipulate a torsion spring in a safer manner than possible in the prior art. A drill or other device can couple to attachment points in mechanical communication with the worm gear to rotate the worm gear at a greater rate, thereby reducing the winding and unwinding time of the torsion spring.