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The types of springs are complex and varied, according to the shape, there are mainly coil springs, volute springs, leaf springs, shaped springs and so on. According to the nature of the force, the spring can be divided into extension springs, compression springs, torsion springs and bending springs. Ordinary cylindrical springs, that is, coil springs due to simple manufacturing, and can be made according to the loaded situation into a variety of forms, simple structure, so the most widely used.

Coil spring is a spring coiled into a shape of the abbreviation. Coiling is the first process of spring manufacturing, but also an important process, the accuracy of the coiling of the entire manufacturing process plays an extremely important role, which basically determines the geometric dimensions and characteristics of the spring as well as the utilization of materials.

The spring production line introduces a typical spring production line consisting of a sequentially connected wire feeder, spring forming machine and spring cutting machine.

Fully automatic wire feederFully automatic wire feeder

It is an automated machine that consists of a material tray, a base, a motor, a speed reducer, a frequency converter, a sensing switch, a relay, and electrical components, etc. It is used in connection with the main machine and is responsible for delivering wire to the main machine. In industrial applications, the fully automatic wire feeder is connected to the host machine (e.g., CNC spring machine and other equipment) to smoothly and continuously deliver wire to the host machine, realizing a high degree of automation with the host machine.

In the initial design concept, fully automatic wire feed frame is mainly for supporting the spring machine to use, that is, the use of frequency converter technology combined with the host's CNC system drive technology, to achieve synchronous and asynchronous control between the two, effectively improving the speed and stability of the spring machine production. With the improvement of modern industrial standardization requirements, various equipment factories continue to improve the application functions of the automatic wire feeder, such as the combination of inductive switches, relays and speed reducers and other electrical components, the function tends to be more intelligent, involving the application of a wider and wider range of fields.

Spring Coilers

Spring coiling machines, also known as CNC spring bending and forming machines, actually produce springs as their main function. The original spring is just a cylindrical tension spring, hand winding, production efficiency is relatively low, it is difficult to adapt to the growing demand for industrial production, especially to process precision springs and heavy equipment required for large springs is very difficult, fortunately, there are a variety of spring coiling machine.

(1) spring coiling machine parts of the institutional composition and function.

Spring coiling machine outlet is fixed, in front of the outlet of the axial distribution of a number of top bar, respectively, used to control the spring coil diameter, pitch and guidance, and a knife, as shown in Figure 3 for the working principle of the spring coiling machine schematic diagram.

1) straightening mechanism. Composition: composed of staggered configuration of the rollers. Role: to eliminate the curvature of the wire coil, which is conducive to improving the precision and resistance of the spring.

2)Feeding mechanism. Composition: a pair or two pairs of rollers. Role: rely on the friction between the roller rotation and the wire to realize the feeding.

3)Guiding mechanism. Composition: composed of upper and lower pairs of guiding plate (guiding plate with circular grooves). Role: to guide the steel wire along the axis of the circular groove in the feeding process to avoid bending of the steel wire before the coil spring.

4) Winding mechanism. Composition: composed of sizing pin and pitch block. Sizing pin to control the diameter of the spring, the pitch block to control the pitch of the spring. Role: winding into a certain shape, diameter, pitch of the coil spring.

5) cut off the mechanism. Composition: by cutting off the knife and mandrel. Role: cut off the spring, control the total number of spring coils.

(2) Working principle. When working, the spring material is fed by the fully automatic wire feeding machine, and then passes through the straightening mechanism and feeding mechanism of the spring coiling machine, when the steel wire touches the groove at the front end of the top bar, it bends and deforms the spring material under the friction effect of the contact point. In the process of bending the spring material into a loop, the wire will touch the beveled surface of the pitch block. The pitch of the spring is made when the pitch mechanism of the spring coiling machine moves the pitch block in the direction of the axis on which the spring is coiled and formed. When coiling helical compression springs with parallel heads (support coils) or helical extension springs, the pitch block is set back so that when the spring is coiled, the latter coil is formed against the already coiled former coil. When a spring is coiled, the feeding mechanism stops feeding and the cutter control machine makes the cutter cut the spring. By repeating this process, the spring is automatically formed.

The curve gauge can move back and forth under the control of the spring diameter change mechanism to adjust the diameter of the spring or to coil a variable diameter coil spring. When coiling variable pitch (unequal pitch) helical compression springs or other helical springs, a pitch cam is required; under the action of the pitch cam, a set of pendulum mechanism pushes the pitch block back and forth to realize the coiling of variable pitch springs.

Other processes after spring coiling

Head Cutting

Purpose: To remove burrs, control the total number of coils of the spring, and leave a certain gap between the coil head and the neighboring coils (conducive to anti-corrosion treatment). Trimming

Purpose: To adjust the parameters such as free height and center diameter of the spring, since the coiled spring may not necessarily meet the requirements of the drawings due to the quality of the steel wire and the precision of the spring winding machine.

Grinding

Purpose: To control the non-perpendicularity of the spring and to improve the force of the spring.

Tempering

Purpose of treatment: Eliminate the internal stress in the steel wire after spring winding, increase the toughness of the material, and stabilize the size and resistance of the spring. Tempering temperature: 180～240℃; holding time: 5～15min.

Anti-corrosion treatment

Purpose: to prevent corrosion, prolong the life, stabilize the spring resistance, commonly used tin-plated or blue.

Strong pressure

Purpose of treatment: to stabilize the size of the spring, but also to expose the hidden problems of the spring. Methods: Static pressure method: the spring will be pressed to the circle and the circle touch (pressure dead), and last for a certain period of time; multiple compression: the spring will be compressed many times (3 to 10 times), each time the pressure to the circle and the circle touch.

This article is mainly for the spring production process used in the general process as well as equipment to do a brief introduction, with the continuous development of CNC spring machine forming technology, the introduction of new technologies, new features of the R & D and application, servo-driven axes to increase the number of artificial intelligence has also been gradually applied, greatly expanding the spring production capacity.