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Synthesis Report I: Project Funded by The Eljropean Community Under The B!? It'Eieuram Programme
Synthesis Report I: Project Funded by The Eljropean Community Under The B!? It'Eieuram Programme
INON-CONFIDENTIAL
CONTRACT N:
BRE2-CT93.890
PROJECT N*:
CR-1247-91
TITLE:
PROJECT
COORDINATOR: Pera
PARTNERS:
* * *
*
**
*
**
* * *
E
DURATION:
21C] MONTHS
NON-CONFIDENTIAL
ABSTRACT
Coiled and helical springs are the most commonly used type of springs, however the manufacturing
process whereby they are coiled has not been fully investigated until now. Within this two year
collaborative research project a novel automated coiling head assembly has been developed and
demonstrated. This assembly controls all the spring machines coiling tip movements wiih very high
levels of accuracy and repeatability. The developed system has been demonstrated in Industry to w=rk
equally well with the machine working on and off line. A camera vision parametric measurement system
for springs, that has also been developed within the project, which when !inked to the cmtrol system
provides for the first time closed loop control of the spring coiljng process. Within the framework of the
project the wire raw material parameters that affect wire boilability have also been investigated and
optimised by using Taguchi experimentation techniques thereby yielding a more robust industrial
process.
The processs finishing operations are generz!!y
well understood and controlled within the spring
making industry. However the c=iling process lS
not, Indeed setting a machine to nake springs of
a certain design can take a skill.?d Coiler a
significant time, anywhere from a few hours to a
few days. The spring manufacture=. conside: the
coiling process to be the cause of the majori> of
manufacturing problems. Furthermore, we
understand that the coiling tip a:ez is the one area
of the production coiling machine that is not
currently commercially available as an autormded
movement in the latest CNC ceiling machines.
INTRODUCTION
Coiled and helical springs are the most commonly
used type of springs in industry today. The
manufacturing process has not changed
significantly in the last fifty years or so. Coiled
springs are most commonly produced from wire
of a circular cross section by the following
continuous process.
SYNTHESIS REPORT
CEC Contract: BRE2-CT93.890
Issue: 1
August 19S5
NON-CONFIDENTIAL
Automated Coiling Head
Undemlandlng
+
I&tint
Require.ments
:101 ;11;1
Coikng Point
Corwpk
Parametric
Meawmment
of Spmg
Conko[ S&km
Taguchl
Co flc2pk
Exp@timenk
,_*_,
L.-J
?.wnd
Pmlotyp d
on
Cam Cok9r
u
Devebp Robust
Manuf. Prams
SYNTHESIS REPORT
CEC Contract: BRE2-CT93.890
Issue: 1
August f 996
NON-CONFIDENTIAL
SYNTHESIS REPORT
CEC Contract: BRE2-CT93.890
Issue: 1
August i 393
NON-CONFIDENTIAL
*
*
TECHNICAL DESCRIPTION
Development of the First prototype design of
coiling head ( see plate 1 )
SYNTHESIS REPORT
CEC Contract: BRE2-CT93,890
Issue: 1
August 1995
NON-CONFIDENTIAL
transducers).
Semo Actuator
Linear Variable Displacement Transducer
Servo Valve
Servo Valve Controller Card
Position Conditioning Card
Electronic Rack
Hydraulic power pack
Distribution manifold and hoses
l=
-
1-
- Hydraulic
servo
Fluid
reserfoir
Electrical connection
Hydraulic connection
SYNTI+ESIS REPORT
CEC Contract: BRE2-CT93.890
Issue: 1
August 1993
NON-CONFIDENTIAL
user interface
Image
Processing
II
\
Data
Manipulation 1
m c COMOI
1
,
!1
Col[ ng
SYNTHESIS REPORT
CEC Contract: BRE2-CT93,890
Issue: 1
Po[nl
t4anlpulat10n
August 19%
NON-CONFIDENTIAL
Parameter
(Resolution)
CCD Camera
diameter, length, sh=~e, quality
(5vm, cycle time 75ms)
Laser scanner
Inductive sensor
Light Barrier
SYNTHESIS REPORT
CEC Contract: BRE2-CT93.890
issue: 1
August 1 SS6
NON-CONFIDENTIAL
e
I
Development
SYNTHESIS REPORT
CEC Contract: BRE2-CT93.890
1.8 seconds
<3.5 mm
et~,~ mm
<0.5 mm
Issue: 1
August 1996
NON-CONFIDENTIAL
approximately 0.01 mm on diameter.
Taguchi
SYNTHESIS REPORT
CEC Contract: BRE2-CT93.890
Experiments
Issue: 1
August f W6
NON-CONFIDENTIAL
accomplished is to determine the effect each
factor has on the overall outcome Gf each
experiment. This is known as the Signal to Nciss
Ratio (S/N ratio dB). As the signal strength rises
compared to the noise strength the variability of
the process is reduced thus allowing greater
quality levels to be achieved.
SYNTHESIS REPORT
CEC Contract: BRE2-CT93.890
10
Issue: 1
August 59S6
NON-CONFIDENTIAL
Setthg the Cam Coiler to produce r.%kwence
springs after the coiling head instal!atirm took
approximately 1 hour. This was acbiewd by the
Coiier giving verbal instructions to t% Control
System Operator, This demonstrated that a
closed-loop control system was a very real
possibility.
established.
The specific objectives of these industrial trials
were:To demonstrate that the hydraulic
actuated coiling tip was robust enough to
withstand the forces associated with
coiling 2mm diameter wire (ie forces up
to 900N) and remain stable when in use
I
I
~
!
I
;+?4
SYNTHESIS REPORT
CEC Contract: BRE2-CT93.890
11
issue: f
Augusi 19:5
NON-CONFIDENTIAL
cylinders when under load. Under this higher
system pressure both coiling tips proved to be
very stable and rigid during coiling
Free length
42,98 mm
Ref Spring
(Without coil head fitted)
First Proto
OD (mm)
22.20
+/-0,1 2mm
+/-O,O7mm
Ref Spring
Mean
Max
Min
hk.cuils
5.80
Pitt>
(mm)
1 OF-5
44.67
45,73
42,83
22.58
22.93
22.20
5.69
580
.560
1 M<
11.5~2
10.32
SYNTHESIS REPORT
CEC Contract: BRE2-CT93.890
OD
(mm)
22.16
FIL
(mm)
42.97
12
Issue: 1
August 1996
NON-CONFIDENTIAL
system including the camera imaging to be
located on a single PC, reducing Iccst and
complexity.
CONCLUSIONS
The project has been successful in independently
SYNTHESIS REPORT
CEC Contract: BRE2-CT93.890
13
Issue: 1
August 1996
.
A
NON-CONFIDENTIAL
ACKNOWLEDGEMENTS
SYNTHESIS REPORT
CEC Contract: BRE2-CT93.89D
REFERENCES
14
1)
2)
Issue: 1
August 19S%
NON<ONFIDENTIAL
. .
HA-r% 1- First Prototype coiling Head Assemkiy during Eknc?l -resm!g =$5J t%2FEi
SYNTHESIS REPORT
CEC Contract: BRE2-CT93.890
15
Issue: 1
Augusi 7996