US2845987A - Spring coiling machine with automatically reciprocating mandrel and automatic wire feeding of broken off end to an automatic pick up on said mandrel - Google Patents

Description

Aug. 5, 1958 H. J. M CULLOUGH 2,345,987

SPRING COILING MACHINE WITH AUTOMATICALLY RECIPROCATING MANDREL AND AUTOMATIC WIRE FEEDING 0F BROKEN OFF END TO AN AUTOMATIC PICK UP ON SAID MANDREL Filed Nov. 23, 1956 l5 Sheets-Sheet 1 i w a E INVENTOR. A'APRY J. Mc CUZ L 0066' BY QM C M Aug. 5, 1958 H. J. MCCULLOUGH 2,845,987

SPRING comuc MACHINE WITH AUTOMATICALLY RECIPROCATING MANDREL AND' AUTOMATIC WIRE FEEDING 0F BROKEN OFF END TO AN AUTOMATIC PICK UP ON SAID MANDREL Filed Nov. 23, 1956 15 Sheets-Sheet 2 1958 H. J. M CULLOUGH 4 8 SPRING COILING MACHINE WITH AUTOMATICALLY RECIPROCATING MANDREL AND AUTOMATIC WIRE FEEDING OF BROKEN OFF END TO AN AUTOMATIC PICK UP ON SAID MANDREL Filed Nov. 23, 1956 v 15 Sheets-Sheet 4 Aug. 5, 1958 NG COILING MACHI NDREL AND U Filed Nov. 23, 1

LOUGH 2,845,987

TOMATI LY RECIPROCATING RE DING BROKEN OFF END ICK ON SAID MANDREL l3 Sheets-Sheet 5 Aug. 5, 1958 H. J. MCCULLOUGH 2,845,987

SPRING comm MACHI w: AUTOMATICALLY RECIPROCATING MANDREL AND AUTOMA W FEEDING BROKEN OFF END up on s TO AN AUTOMATIC PICK MANDREIL Filed Nov. 25, 1956 15 Sheets-Sheet 6 Aug. 5, 1958 .J. M c LOUGH 2,

SPRING COILING-MA NE WITH TOMATICALLY RECIPROCA G MANDREL AND AUTOMAT WIRE FEEDING OF BROKEN OFF E AN UP ON TO AUTOMA PICK SAID MANDREL I I Filed NOV. 23, 1956 Y 13 Sheets-Sheet 7 INVENTOR. HAAA) J. Me C (/ZLOOG/l ATZURNE'YS Aug. 5, 1958 H. J. M CULLOUGH 2,

SPRING COILING MACHINE WITH AUTOMATICALLY RECIPROCATING MANDREL AND AUTOMATIC WIRE FEEDING OF BROKEN OFF END TO AN AUTOMATIC PICK UP ON SAID MANDREL Filed Nov. 23, 1956 13 Sheets-Sheet 8 FIG ' 5, 1958 H. J. MCCULLOUGH 2,845,987

SPRING COILING MACHINE WITH AUTOMATICALLY RECIPROCATING MANDREL AND AUTOMATIC WIRE FEEDING OF BROKEN OFF END ,TO AN AUTOMATIC PICK UP ON SAID MANDREL Filed Nov. 25, 1956 13 Sheets-Sheet 9 Aug. 5, 1958 H. J. M CULLOUGH 2,845,987

SPRING COILING MACHINE WITH AUTOMATICALLY RECIPROCATING MANDREL AND AUTOMATIC WIRE FEEDING OF BROKEN OFF END TO AN AUTOMATIC PICK UP ON SAID MANDREL Filed Nov. 23, 1956 15 Sheets-Sheet 10 I INVENTOR. HARRY J. MC CUZZOI/Gh' BY QM M M/ Walk/WM AY'ZdKZ/A'YS' g- 58 H. J. MOCULLOUGH 2,845,987

SPRING comma mourns WITH AUTOMATICALLY RECIPROCATING MANDREL AND AUTOMATIC WIRE FEEDING OF BROKEN OFF END TO AN AUTOMATIC PICK up ON SAID MANDREL Filed Nov. 25, 1956 1:5 Sheei-Sheet 11 Aug. 5, 1958 H. J. MCCULLOUGH 2,845,987

SPRING comm; MACHINE WITH AUTOMATICALLY RECIPROCATING MANDREL AND AUTOMATIC WIRE FEEDING OF BROKEN OFF END TO AN AUTOMATIC PICK UP ON SAID MANDREIL Filed Nov. 25, 1956 15 Sheets-Sheet 12 Aug. 5, 1958 I H. J. MGCULLOUGH 2,845,987

SPRING comma MACHINE WITH AUTOMATICALLY RECIPROCATING MANDREL AND AUTOMATIC WIRE FEEDING 0F BROKEN OFF END TO AN AUTOMATIC PICK up ONSAID MANDREL.

Filed Nov. 23, 1956 13 Sheets-Sheet 13 United States Patent SPRING COILING MACHINE WITH AUTOMATI- CALLY RECIPROCATING MANDREL AND AUTOMATIC WIRE FEEDING OF BROKEN OFF END TO AN AUTOMATIC PICK UP ON SAID MANDREL Harry J. McCullough, Redwood City, Calif., assignor to Federal-Mogul-Bower Bearings, Inc., Detroit, Mich., a corporation of Michigan Application November 23, 1956, Serial No. 624,107

37 Claims. 01. 153-67) This invention relates to a fully automatic machine for making helical springs.

The invention is particularly useful for making smalldiameter, close-wound helical springs such as the garter springs used to maintain the sealing lips of oil seals in contact with a rotating shaft, but it is also applicable to springs of larger diameter and to open-wound springs.

Heretofore, spring-winding machines have required the constant attention of an operator who, at the most, could operate no more than two machines simultaneously, since he had to trip a device for locking the straight wire to a mandrel at the commencement of each spring, and then, after the machine had completed coiling the spring, had to manually withdraw the spring from the mandrel and return the machine to its beginning position to start the next spring. The hand labor required haskept manufacturing costs high, and the work has been montonous and wearying.

One object of the present invention is to provide a fully automatic device for producing helical springs. A machine constructed according to the principles of this invention operates continuously and begins a new spring as soon as the old one is completed. One operator can look after many machines, because all he has to do is, from time to time, to install a new spool of spring wire when an old spool has been used up, to change a very few key parts and settings when a different diameter, coil-spacing, or length of spring is to be produced, and to service the machine from time to time, according to its needs. This contrasts with one operator having to devote his full time to run two machines of the best type available in the prior art, and having to have an additional maintenance crew.

Another object of the invention is to provide a significant increase in production per machine, as well as per operator. A machine embodying the present invention can wind springs several times as fast as a hand operated machine, much faster even than an operator using two of the old machines. For example, machines embodying the present invention have produced 630 relatively long garter springs per hour, Whereas a single highly skilled operator running two prior-art machines could produce a maximum of about 490 springs of the same type per hour, or 245 per machine. With shorter springs, the difference becomes even greater; the new machines have produced 1,200 per hour of a short spring as against 700 per hour with two hand-operated machines, or 350 per machine.

A corollary object of the invention is to reduce the number of machines needed for spring production by providing machines which operate very fast and which are fully automatic. Obviously, the achievement of these objects results in both lower capital investment in tools and building space occupied, and lower production expense.

Another object of the invention is to provide a fully automatic machine for winding both close-wound springs (where the adjacent coils touch and open-wound springs of various coil spacings.

2,845,987} Patented Aug. 5, 1958 In order to achieve these objects, many specific problems had to be solved. However, these can hardly be understood without reference to the structure of the machine. Therefore, other objects and advantages of the invention will appear from the following description of a preferred embodiment thereof. i

In the drawings:

Fig. 1 is a photographic view, generally in front elevation, of a machine embodying the principles of the present invention. i t

Fig. 2 is an enlarged front elevation view, pa'rtly in section, of the upper portion'of the machine, shown on three sheets, because of the problem of scale: Fig. 2A shows the portion on the right of the machine of Fig. 1, Fig. 2B the central portion, and Fig. 20 the portion on the left. Some parts have been removed for the sake of clarity.

Fig. 3 is a vertical sectional view taken along the line 33 in Fig. 2A.

Fig. 4 is a view in vertical section taken along the line 44 of Fig. 2A and showing the wire-feeding assembly and adjacent parts. The wire tensioning and wire-advancing rolls are shown in their outermost position.

Fig. 5 is a view similar to Fig. 4 but showingonly a portion thereof and with the wire-tensioning and wireadvancing rolls shown in their innermost position, with the wire thereby advanced. p

Fig. 6 is a view in vertical section taken along the line 66 of Fig. 2B, showing the spring wire pickup mechanism, the mandrel supporting device, and adjacent parts.

Fig. 7 is a view in vertical section taken along the line 7-7 of Fig. 2B.

Fig. 8 is a view in vertical section taken along the lines 8 8 of Fig. 2C.

Fig. 9 is a photographic perspective view of the wirefeeding assembly, shown moved apart from the-Wirepickup device with the mandrel connecting them.

Fig. 10 is a view in vertical section taken along the line 10-10 in Fig. 4, but on an enlarged scale, showing the wire-tensioning and advancing rollers.

Fig. 11 is an enlarged elevation view .of a portion of Fig. 4 showing the eye that feeds wire onto the mandrel, the wire being shown in broken lines.-

Fig. 12 is a view in verticalsection taken along the line 12r-12 in Fig. 11. The spring is shown being coiled 7 around the mandrel end, pushing the carriage .to the right.

Fig. 13 is a view in horizontal section-taken along the line 13-13 in Fig. 11.

Fig. 14 is a view in perspective showing the eye block which feeds the wire to the mandrel and the notched bearing plate behind it, against which the last coil of the coiled wire pushes to move the feeding sub-assembly carriage along the frame.

Fig. 15 is a top plan view of the wire-feeding assembly, on an enlarged scale with respect to Fig. 4, showing its pivoted mounting on its carriage, a different position being shown in broken lines. I

Fig. 16 is a photographic perspective view of the wirepickup device, with the revolving chuck and adjacent parts.

Fig. 17 is an electrical circuit diagram with the microswitches and their tripping apparatus shown in halfdiagrammatic, half-representational form, generally in plan, but partly in elevation, and with the pneumatic valves and their parts controlled by them shown in the position where the wire has been fully wound into a spring and the mandrel mostly retracted from within the spring. The microswitches are shown diagrammatically and no attempts made to show their levers pictorially in the positions shown in Fig. 1.

Fig. 18 is a diagram similar to the top portion. of Fig.

17 showing the mandrel fully retracted, the completed spring dropped out of view, and the machine about to begin a new cycle.

. Fig. 19 is a view similar to Fig. 18 showing the next step in the cycle, Where the mandrel and the feeding assembly are moving toward each other and a length of wire is being advanced through the feeding eye.

Fig. 20 is a view similar to Fig. 19, showing the next step in the cycle with the wire-pickup device just picking up the Wire and starting a new spring.

Fig. 21 is a view similar to Fig. 20 showing the next step, in the cycle, with the wire-advancing rollers moving out and the spring partly wound.

- Fig. 22 is a view similar to Fig. 21 showing the next step thereafter. and just before Fig. 17, with the spring nearly wound.

GENERAL DESCRIPTION OF THE MACHINE I Thejmachine shown'overall in Fig. 1, and in more detail in' the other'drawings, is a unitary apparatus operated by pneumatic and electrical devices. For convenience, it may have a base frame 25 provided at one end with a cabinet 26 housing various switches, timers, and other appropriate parts of the machine, the principal ones being shown diagrammatically in Figs. 117-22.

The upper end 27 of the frame 25 supports a wire-feeding assembly A, a wire-winding assembly B, and a series of microswitches and other controls that govern the cycle of operations. The wire-winding assembly B does not move" along the frame 25; it includes a rotating spindle 30 that drives a rotating wire-pickup device 31 and a retractable rotating mandrel 32. The wire-feeding assembly A is mounted on a carriage 33 for rolling movement along the frame portion 27 toward and away from the wirewinding assembly B.

In brief, the wire-feeding assembly A takes wire W from a spool or reel R (Fig. 17 and advances it through an. eye assembly 34 that turns the wire W over an angle of substantially 90 degrees to its original direction of travel and projects it toward the wire-winding assembly B. The other end of the wire W is caught by the rotating pickup device 31 and wrapped about the mandrel 32. As the wire W is wound around the mandrel 32, it pushes the carriage 33 along the mandrel 32 away from the pickup device 31, so that (in a close-wound spring) the carriage 33 moves a distance equal to the diameter of the wire W for every rotation of the pickup 31, thereby forming. a close-wound coil spring S. At the predetermined spring length, the wire W reaches the end of the mandrel 32 and is therefore broken off automatically, completing the spring S. The carriage 33 is then propelled in the other direction to move the wire-feeding assembly A up close to the wire-winding assembly B, and the next spring is started.

A. The wire-feeding assembly a (1) THE WIRE-ADVANCING AND TENSIONING MECH- ANISM (SEE PARTICULARLY FIGS. 4, 5, 9, 10 AND 16) A long length of wire W may be provided by a reel or spool R (see Fig. 17) mounted adjacent the machine for free rotation, and the wire W may be strung from there to the wire-feeding assembly A. At the assembly A, the wire first passes through a guide eye 34a and then between a pair of rollers 35, 36 (see Figs. 4, 5, and 10). Theupper roller,35 preferably has a knurled cylindrical surface 37, while the lower one 36 preferably has a wire receiving circumferential guide groove 38, preferably just too shallow to receive the full diameter of the wire therein, so that the upper roller 35 engages it. The rollers 35, 36 both guide and tension the wire W during the winding of the spring S and thereby regulate the tension of the finished spring S. Also, during the starting operation for each spring S, the rollers 3536 advance the wire W a short distance (about one inch) forward'th'rough the eye 34 to a position where its end 39 sticks out and can be caught by the pickup device 31 (see Fig. 16).

The lower roller 36 may be rotatably mounted to a reciprocating carriage bar 40 by means of a stub axle 41. The upper roller 35 is also rotatably mounted, preferably on a stub shaft 42 that is carried by an arm 43, which, in turn, is secured pivotally by a pin 44 to the carriage bar 40. A thumb screw 45 is threaded through a projection 46 on the carriage 40 and supports one end of a perforated leaf spring 47, through the perforation 47a of which the screw 45 extends. The other end of the leaf spring 47 bears against the arm 43, and a stationary cylindrical fulcrum 48 bears on the opposite side of the spring 47 in between the thumb screw 45 and the arm 43. By tightening the screw 45 inwardly, the spring pressure on the arm 43 is increased, forcing the upper roller 35 more tightly against the wire W and the roller 36, to increase the tension between the rollers 35, 36 and on the wire W. By threading-the screw 45 outwardly, the tension is relaxed. The tension is adjusted to whatever amount is desired.

The carriage bar 40, which carries the two rollers 35, 36 and the screw 45, is slidably mounted on a guideway 49 that may be an integral portion of a pivotally mounted supporting bar or frame 50 of the wire-feeding assembly A. The carriage bar 40 is provided with a dovetail slot 51 and is moved back and forth along the guideway 49 by a pneumatic cylinder 52 pivotally mounted on a frame member 74 with its piston 53 connected rigidly by a rod 54 to the carriage bar 40. When the piston 53 is in the position shown in Fig. 4, the carriage bar 40 is in its outermost position. When the piston 53 is in the position shown in Fig. 5, the carriage 40 is moved to its innermost position and, since the rollers 35, 36 are tensioned about the wire W, the movement from Fig. 4 to Fig. 5, advances the wire W in an amount equal to the stroke of the piston 53, sending the end 39 of the wire W out of the eye 34 for about one inch.

The cylinder 52 is provided with a left-hand (instroke air) port 55 and a right-hand (outstroke air) port 56, connected respectively by flexible conduits 57, 58 (see Figs. 9 and 17) to a double-action air'valve 60 oper ated by two solenoids 61, 62. The solenoid 61, when energized (see Fig. 21) acts to move a valve member 63 (Fig. 17 to close a port 64 and open a port 65, thereby sending air through the conduit 58 into the right- 'hand port 56 of the cylinder 52, moving the piston 53 and carriage 54 out. The other solenoid 62, when encrgized (see Fig. 19), acts to move the piston 53 and carriage in (to the right, from Fig. 4 to Fig. 5) by moving the valve member 63 to close the port 65 and open the port 64.

The wire W fed from the rollers 35, 36 passes through a guide groove 66 (Fig. 4, dotted lines) that extends horizontally along the rear face of a block 67 up to the eye assembly 34, where the wire W is to be turned at substantially a right angle and where the spring-winding takes place.

To support the Wire W (particularly with a smalldiameter wire) a column support member 68 is provided, with a cylindrical groove through which the wire W passes. The column support member 68 is carried bya spring-mounted arm 69 that is slidably mounted in and guided by a recess in the frame 50. As shown by Figs. 4 and 5, the forward edge 69a of the carriage bar 40 catches the column support member 63 and moves it along as the carriage bar 40 moves from its Fig. 4 position to its Fig. 5 position. When the carriage 40 moves back to its Fig. 4 position, the column-support member 63 is spring-urged back to its Fig. 4 position midway between the rollers 35, 36 and the block 67.

(2) THE EYE ASSEMBLY 34 (SEE FIGS. 4:, 5, 9 AND 11-15) The eye assembly 34 includes a notched and grooved eye block 70, a V-notched bearing plate 71, a concavely faced turning guide member 72, and a mandrel-steadying V-notched block 73. Of these, the eye-block 70 and bearing plate 71 are rigidly secured to the pivotally mounted frame 50, while the guide member 72 and block 73 (which may be portions of an integral piece) are secured to a frame member 74 that is rigidly mounted on the carriage 33.

The eye block 70 has an open-end slot or eye 75 whose inner end is preferably semi-circular, the outer portion comprising tangential extensions. A wire-guiding groove 76 in the inner face 77 of the eye block 70 lies in line with the groove 38 in the roller 36 and with the groove 66 and also lies tangential to the upper edge 78 of the eye 75, so that the wire W is fed against and guided by the upper edge 78.

The eye block 70 is slidably mounted on the bearing plate 71, a flat lower edge 79 of the block 70 riding on a flat shelf 80 of the plate 71, and a sloping upper edge 81 of the block 70 fitting in a sloping groove 82 in the plate 71. Lateral adjustment (see Fig. 11) relative to the plate 71 is provided by means of an elongated slot 83 through the block 70 and a set screw 84 threaded into the plate 71.

The bearing plate 71 has a V-shaped notch 85 (best shown in Fig. 14) generally in line with the eye 75 but not so deep, so that a plane surface area 86 lies behind the semi-circular portion of the eye 75. This area 86 serves as a bearing surface against which the coiled wire W bears as it is wound, and through which it transmits the force which moves the carriage 33 away from the spring-winding assembly A.

By moving the plate 71 to the right or left as seen in Fig. 11, the V-notch 85 can be adapted to take various sizes of mandrels 32. For this purpose, the plate 71 is adjustably mounted with respect to the frame 50 by means of a pair of elongated slots 87, 87 and a corresponding pair of set screws 88, 88.

On the opposite side of the mandrel 32 from the bearing plate 71, but preferably not in the same plane (see Figs. 12 and 13), is the V-notehed block 73, which serves to steady the mandrel 32 by its V-notch 89 engaging the mandrel 32 on the side opposite from the V-notch 85. As stated earlier, the block 73 and the guide member 72 may be made in one piece.

As the wire W comes through the eye 75 (being propelled initially by the translation of the two rollers 35, 36 with their carriage bar 40 by the cylinder 52 and later being pulled by the pickup 31), it comes out from the groove 76 and moves along the upper surface 78 of the eye 75. Then it engages a concave, rather conical surface 90 formed in the guiding and turning block 72, the shape of the surface 90 causing the wire W to turn substantially 90 degrees into a position where its outer end 39 can be engaged by the pickup device 31 in a manner to be described.

3 ADDITIONAL TENSIONING DEVICE (SEE FIGS.

- 2A, 9 AND 15 An additional device for tensioning the wire W, and also for making it possible to wind open-wound as well as close-wound coil springs, is provided by means for regulating the rotational position of the frame 50 on the carriage 33. For this purpose, the frame 50 and the cylinder 52 are supported at one end 91 by a pair of aligned vertical pivot pins 92, so that cylinder 52 and the frame 50 with all of its parts can be rotated while remaining in a substantially vertical plane. As will be noted from Figs. 4, 5, 9 and 15, the pivot pins 92 are vertically above and below the mandrel 32 and are secured to the stationary frame member 74 which, in turn, is rigidly mounted on the carriage 33.

A set-screw may be provided to hold the frame 50 in any desired rotational position, but preferably means outboard of the pivot 92 are provided for retaining the frame 50 at whatever angle is desired. This retaining means includes a bracket arm 93 rigidly supported by the carriage 33. A threaded rod or screw 94 extends through and is threadably engaged with the bracket arm 93 and at its inner end is provided with a rubber bumper 95 that engages the block 67. Therefore, the frame 50 may be swung clockwise (as seen in Fig. 15) to any desired position by turning the screw 94 to move it in relative to the bracket arm 93, the bumper 95 pushing the block 67 and therefore swinging the frame 50 around the pivots 92. A lock nut 96a may then be tightened against the bracket arm 93 to hold the screw 94 and bumper 95 firmly in position. This adjustment holds the frame 50 against counter-clockwise rotation as seen in Fig. 15.

To hold the frame 50 snugly against the bumper 95 and against further rotation in a clockwise direction, the frame 50 is connected at a pivot 96 to a rigid rod 97 which compresses a spring 98 inside a cylinder 99 that is mounted pivotally on the carriage 33. Thus, the spring 98 urges the frame 50 counter-clockwise (Fig. 15) toward the wire-winding assembly B, while the bumper 95 urges the frame 50 in the opposite direction.

Obviously, rotation of the frame 50 does not change the basic operation of any of the parts mounted thereon. But it does change the relation between the pivoted frame 50 and he stationary frame 74 and therefore changes the relation between the eye 75 and the concave face 90 of the guide member 72. As a result, when the wire W is wound around the mandrel 32, it is subject to different tensions, depending on the rotational position of the frame 50. The tension herein cooperates to a certain extent with that placed on the wire W by the rollers 35, 36 to vary the tension of a finished close-wound spring S. In addition, when the angle is great enough, as in the instance of the broken-line position of the frame 50 shown in Fig. 15, the

(4) MANDREL END STEADYING DEVICE (FIGS. 2A,

' 9, AND 15) The carriage 33 rigidly supports a mandrel-steadying tube 100, by means of a bracket arm 101 and the same frame member 74 that pivotally supports the frame 50 and rigidly suppotrs the blocks 72 and 73. In line with the V-notch block 73, and spaced from it, is a 'conically inwardly tapered opening 102 adapted to guide the front end of a mandrel 32 into the cylindrical tube 100. The tube and opening 102 hold the outboard end of the mandrel 32 steady during the winding of the spring S and keep it from vibrating. Additional steadying is provided by the V-notched blocks 71 and 73.

5 MOVEMENT OF THE CARRIAGE ALONG THE FRAME (FIGS. 1, 2A, 2B, 3, 4, 9 AND 17 The carriage 33 is mounted on ball bearings 109 for movement along'two smooth, cylindrical shafts 105 and 106 that extend axially of the frame 25 and are supported at their ends by frame members 107 and 108. The carriage 33 is provided with three cylindrical ball bearings 109 which enclose and ride on the cylindrical shafts 105, 106 with a low-friction sliding engagement therewith, so that the carriage 33 can be reciprocated on the frame 27 by the application of very low forces.

- As already stated, the carriage 33 is pushed away from the spring-winding assembly B by the pressure of the last coil of the spring itself on the bearing surface 86. After each spring S is completed, movement of the carriage 33 in the opposite direction toward the pick-up assembly 31 is accomplished by a pneumatic cylinder 110, which is supported rigidly on the frame 27. The cylinder 110 has its piston 111 provided with a long extension rod 112 that extends parallel to the stationary shafts 105 and 106 and is provided at its outer end 113 with a carriage return member 114 that has a grooved guide portion 115 mounted for sliding movement along a guide track 116.

7 (Figs. 2A and 4). Movement to the right, as seen in Fig. 2A, is limited by a stop 117.

The'up'per end of the carriage return member 114 provides an engaging surface 118. The carriage 33 has a depending cylindrical portion 120 through which a rod 121 is mounted for sliding reciprocating movement. A spring 122 is mounted for compression between the cylindrical portion 120 and a collar 123 secured near the outer end of the rod 121. The carriage surface 118 strikes the rod 121 when the carriage return member 114 moves to the left (Fig. 2A), first compressing the spring 122 and, when the spring 122 has absorbed the initial shock, moves the carriage 33 to the left, toward the wire-winding assembly B.

The lower end of the carriage return member 114 is provided with an extension 124 that is adapted to serially engage three normally open microswitches 125, 126 and 127, reading from right to left in Figs. 2A and 17, whose respective lever arms 128 are preferably provided with rollers 129 and are mounted so that the microswitches 125 and 127 are engaged at the respective limits of the stroke of the carriage return member 114, while the microswitch 126 is closed only momentarily during movement of the member 114 from right to left, or left to right. As shown in Fig. 17, the microswitch 125 energizes and de-energizes the solenoid 61, and the microswitch 126 energizes and de-energizes the solenoid 62 (it also energizes and deenergizes the solenoid 233, as will be explained later).

Operation of the cylinder 110 is controlled by a pneumatic valve 130 (Figs. 17-21), whose movable valve member 131 is slid in one direction upon energization of a solenoid 132 to open a port 133 and close a port 134, and in the other direction upon energization of a solenoid 135 to close the port 133 and open the port 134. The valve port 133 is connected through an air conduit 136 to the left-hand end 137 of the cylinder 130 and, when opened by energization of the solenoid 132, sends air into the left-hand end 137 to move the piston 111, rod 112, and carriage return member 114 to the right. Similarly, the valve port 134 is connected through an air conduit 138 to the right-hand end 139 of the cylinder 130, and, when opened by energization of the solenoid 135, sends air into the right-hand end 139 of the cylinder 130 and moves the piston 111, rod 112, and carriage return member 114 to the left.

As shown by Fig. 17, the solenoid 132 is energized and de-energized by the microswitch 127. Thus, when the carriage return member 114 completes its full stroke to the left, it automatically closes the switch 127, energizing he solenoid 132 and sending air into the left end 137 of the cylinder 130, immediately sending carriage return member 114 out to the right. This means that the carriage return member 114 returns the carriage 33 up to where the wire-feeding assembly A is close to the wire-winding assembly B; then the carriage return member 114 is immediately moved to the right so that it will not hamper the free movement of the carriage 33 under action of the spring S pressing against the bearing surface 86.

Energization of the solenoid 135 will be discussed later, since its actuation is by a portion of the wire-winding assembly B.

The carriage 33 also has a depending actuating member 140 that is adapted to engage and actuate a microswitch 141 by engaging its lever roller 142 (see Fig. 4 and Fig. 2A). This exercises a control on the wirewinding assembly B, and its explanation also must be deferred for a while.

All the microswitches 125, 126, 127 and 141 are mounted to enable adjustments along the frame 25, so that their actuation position can be readily adjusted. The microswitches 125, 126, 127 are slidably mounted on a cylindrical rod 143 supported by frame members 144 and 145, a screw-adjusted clamp 146 supporting each microswitch 125, 126 and 127 in the desired position 8 (see Figs. 2A and 4). Similarly, a generally cylindrical rod 147 (one side 148 may be planar to prevent undesirable rotation) supports, the microswitch 141 so that it is adjustable along the rod 147 lengthwise of the frame 27 to determine where it will be engaged by the actuating member 140. The rod 147 is supported by the frame support members 107 and 108.

(6) STEADYING OF THE COIL SPRING S AND MANDREL 32 DURING THE SPRING-WINDING OPERATION (FIGS. 4, 9, AND 16) The rod 147 also supports for lengthwise adjustment a mandrel-and-spring steadying device 150. Its base 151 is mounted slidably on the rod 147, the planar side 148 retaining its rotational position, and it may be tightened in any desired lengthwise position by clamp screws 152. A cylindrical sleeve 153 extends transversely through the base 151 and is rigidly secured to it. A cylindrical rod 154 is mounted slidably inside the sleeve 153 and is provided with a V-notched block 155 at one end and a stop member 156 at the other end. The rod 154 is springurged (by a spring 154a) inside the sleeve 153 to move toward the left (when seen as in Fig. 4) to project the block 155 toward the mandrel 32, movement in that direction being stopped by the stop member 156.

The tube 153 has an axially extending slot on its lower end, along which moves a guide member 157 provided with a cam roller 158. The roller 158 is engaged by a cam 160 on the carriage 33, having a lengthwise portion 161 parallel to the shaft 105 and mandrel 32, and an angular portion 162. When the carriage 33 moves toward the wire-winding assembly B, the cam 160 engages the roller 158 with its portion 162 and retracts the block 155 so that it will not get in the way between the eye assembly 34 and the pickup assembly 31. Further movement of the carriage 33 toward the Wire-winding assembly B moves the roller 158 along the cam por-. tion 161, holding it out of the way. As the spring S is wound and the carriage 33 is pushed back, the cam portion 162 returns the steady block 155 slowly toward and then against the spring S, to steady it and the mandrel 32 as the spring S gets longer.

B. The wire-winding assembly B (1) THE PICKUP DEVICE 31 (FIGS. 2B, 6 AND 16) As stated earlier, the wire-winding assembly 13 includes the rotating spindle 30, which is driven at a constant speed during the operation of the machine. At one end of the spindle 30 is affixed the pickup device 31- comprising a threaded chuck 200 having a recessed end 201 providing a flat disc portion 202. A mandrel support member 203 is provided on one side of an opening 204 through which the mandrel 32 may be moved in and out. The member 203 supports about of the mandrel 32 and prevents it from bending when the wire.

W is initially wrapped around it. An elongated slot 205 and a set screw 206 provide for radial movement of the member 203, to adjust for various sizes of mandrels 32.

Opposite the mandrel support member 203 is a hook assembly 210 which may be an integral member. It has a generally flat disc segment 211 pivotally secured by a pivot member 212 to the disc portion 202 and locked in a desired rotational position by means of a clamp screw 213 in an arcuate slot 214. The rotation of the disc segment 211 enables adjustment to different sizes of mandrels 32 while retaining the proper rotational position.

Projecting out from the disc segment 211 is a hook 215 having a notch 216 and a ledge 217 that engage the free end 39 of the wire W when the eye assembly 34 and the pickup device 31 are close together. The pickup notch 216 engages the wire end 39 and, since the spindle 30 is turning rapidly, turns the wire W around the mandrel 32, which is also rotated by the spindle 30 at the same speed. The hook 215, being shaped to force the wire towards its inner surface, thus catches the wire and" locks it in place for forming the entire length of the spring, until the wire breaks off at the end of the mandrel 32, releasing the tension on the pickup 31, thus causing the spring S to free itself from the pickup 31.

(2) THE MANDBEL 32 (FIGS. 23, 9 AND 16) The mandrel 32 is made long enough to project beyond the chuck face 202 slightly more than the length of the spring S. While the mandrel 32 is being turned, the spring S is being wound, the wire W is being pulled through the tensioning rollers 35, 36 and through the eye assembly 74, and that portion of the spring bearing against the flat surface 86 forces the carriage 33 back away as the spring S is wound. When the carriage 33 has been pushed so far that the wire W passes beyond the end of the mandrel 32, the wire W bends sharply on itself and breaks off. In order that the moment of breakage be not critical, the microswitch 141 (which controls the retraction of the mandrel 32 in a manner to be explained below) is connected to a time delay switch 220, so that themandrel 32 is not withdrawn until the wire W has actually been broken.

Once the wire W has been broken, it is time to withdraw the mandrel 32. This is accomplished by means of a pneumatic cylinder 221 with a piston 222 and a rod 223. The rod 223 is connected to a cross-head 224, (Fig. 7) which rides on three parallel, cylindrical, stationary guidway shafts 225, 226 and 227 supported by the frame 27 from supporting members 228 (Fig. 2C) and 229 (Fig. 2B). The cylinder 221 is supported on the frame 27 by a pair of supporting members 221a and 229, one at each end thereof.

The air to the pneumatic cylinder 221 is controlled by a valve 230 which, in turn, has a movable valve member 231 controlled by a pair of solenoids 232 and 233. Energization of the solenoid 232 (by the microswitch 141 through the time delay switch 220) moves the valve 231 to the left (Fig. 17) and closes a port 234 while opening a port 235, thereby sending air through a conduit 236 to the right-hand end 237 of the cylinder 221. This moves the piston 222 to the left and retracts the mandrel 32. Similarly, energization of the solenoid 233 (by the actuation of the microswitch 126) moves the valve member 231 to the right, closes the port 235, opens the port 234, and sends air through a conduit 238 to the left end 239 of the'cylinder 221. This moves the piston 222 to the right and projects the mandrel 32.

The cross-head 224 (see Fig. 2B) supports a rotating shaft 240 by means of a ball-bearing assembly 241, the shaft 240 being anchored to the ball-bearing assembly 241 by a nut 242 threaded on the shaft end 243. The shaft 240 is splined to the rotating spindle 30, which rotates in a housing 244 by virtue of ball- bearings 245 and 246 at each end thereof. Atits forward end, the shaft 240 supports a chuck 247 that, in turn, is clamped about the mandrel 32. Thus, the spindle 30, driven by a belt 248 on the pulley 249, turns not only the pickup assembly 31 but also the shaft 240 and the mandrel 32, all at the same speed.

Being splined or keyed by a full-length keyway to the spindle 30 and slidable therein, the shaft 240 rotates with the spindle 30 in all lengthwise positions. Thus, when the piston 222 moves to the left (as seen in Fig. 2B), the cross-head 224 and the shaft 240 move to the left and retract the mandrel 32 back to the point where it no longer projects out as far as the hook 215, and if a spring S is on the mandrel 32, it is stripped off by the mandrel support member 203 and the hook assembly 210. Being stripped off, the finished spring S falls down between a pair of converging frame side members 250 and 251 (Figs. 3, 4, and 6) and through a discharge opening 252. A slide, conveyor or other device (not shown) may carry the springs S away from the machine, or they may be collected in a suitable container placed below the opening 252. When the spring S has been .10 automatically stripped from the mandrel 32 in the manner described, the piston 222, crosshe'ad 224,.shaft 240, and mandrel 32 are moved to the right to start another spring.

3 MICROSWI'ICH ACTUATION BY THE. CROSS- HEAD 224 The cross-head 224 is used not only'to tie the piston 222 and the mandrel 32 together and to insure perfect alignment and longitudinal movement, but also ate a series of microswitches.

A normally closed safety microswitch 260 (see Figs. 17 and 2B) is permanently mounted adjacent the rear end of the housing 244 so that .it is always engaged and opened when the cross-head 224 is adjacent the housing 244, holding the mandrel 32 in its fully advanced position. Being opened, the microswitch 260 thereby prevents accidental actuation of a normally open microswitch 261 (Figs. 2C and 8) from causing unwantedjretraction of the carriage return 114. The microswitch 261 is engaged and closed by the cross-head 224 at the outer limit of its stroke to energize the solenoid 135, thereby causing the return of the carriage 33 toward the pickup device 31, the safety microswitch 260 then being closed.

Another microswitch 262 is also engaged by the crosshead 224 at the outer limit of its stroke. The microswitch 262 is a safety one, normally closed, and opened only when the cross-head 224 engages it. It is connected in series between the microswitch 141 and the time delay switch 220 and when opened breaks the circuit so that air does not continue to blow through the valve during the period of tripping of the microswitch 261 by the crosshead 224 and the movement of the carriage 33 away from the microswitch 141. i

The microswitches 261 and 262 are mounted adjust-' ably so that they can quickly be adjusted to correspond with any desired length of mandrel 32 to limit the stroke thereof and insure proper engagement. For this purpose, the microswitches 261 and 262 are mounted on a carriage 263 (Figs. 2C and 8), which is provided with bearings 264, 265, 266 permitting free sliding along the stationary ways of the shafts 225, 226 and 227. A threaded rod 267 is rotatably mounted in hearings in the frame support members 228 and 229 provided with a handle 268. The rod 267 is threaded through the'microswitch carriage 263 and passes through the cross-head 224 with clearance and without engagement. The functions performed by the rod 267 and handle 268 are to adjust accurately the position where the cross-head 224 engages the microswitches 261 and 262 and to act as bumper stops for the cross-head 224, thus keeping the mandrel end from pulling into the mandrel guide 204 further than desired. p

C. Controls (1) THE PNEUMATIC CIRCUITRY (FIG. 17)

(2) THE ELECTRIC CIRCUITRY (FIGil'l) The electric circuitry is also simple. A single source of electric power 280 may be used to run a motor 281 that turns the spindle 30 and to provide the power for the solenoids and microswitches. Thus, the source 280 of power (such as an A.-C. power line) is connected to the normally open microswitch by a lead 282, and

the microswitch 125 is connected to the 'ungrounded side of the solenoid 61 by a lead 283. Similarly, one side of the normally openmicroswitch to actu-' 11 126 is connected by a lead 284 to the power source 280, while its other side is connected by a lead 285 to the ungrounded side of the solenoid 62 and by a lead 286 to the ungrounded side of the solenoid 233.

The power source 280 is connected to the time-delay switch 220 by a lead 289. The time-delay switch 220 is connected by a lead 290 to the normally open microswitch 141, by a lead 291 to the ungrounded side of the solenoid 232, and by a lead 292, to the normally closed microswitch 262, which in turn is connected to the microswitch 141 by a lead 293. Closing the microswitch 141 energizes the time-delay switch 220, so that after a short interval of time the solenoid 232 is energized, and the solenoid 232 is de-energized when the normally closed microswitch 262 is opened.

The normally open microswitch 261 is connected to the 'power source 280 by a lead 294 and to the solenoid 135 via a lead 295, the normally-closed microswitch 260 and a lead 296.

D. Operation (Figs. 17-21) The machine operates in a continuous cycle, so that one might as well begin at Fig. 17 where a spring S has just been completed, and the mandrel 32 is being retracted. Retraction of the mandrel 32 causes the completed spring S to drop down between the frame members 25,0 and 251 and out through the discharge opening 252. f

The piston 222, rod 223, and cross-head 224 are moving to the left in Fig. 17, retracting the shaft 240 and the mandrel 32. The normally closed microswitch 260 has been closed when the cross-head 224 moved away from it and the cross-head 224 is moving toward the microswitches 261 and 262.

' In Fig. 18 the cross-head 224 reaches the microswitches 261 and 262, closing the normally-open microswitch 261 and opening the normally-closed microswitch 262. Opening the microswitch 262 opens the time-delay switch 220 and de energizes the solenoid 232, irrespective of the fact that the microswitch 141 is still closed. Closing the microswitch 261 sends current through the lead 295, the closed safety-microswitch 260, and the lead 296 to energize the solenoid 135. This action sends air from the valve 130 through the port 134 into the right end of the cylinder 110 and moves the piston 111, rod 112, and carriage return member 114 to the left.

In Fig. '19, the carriage return member 114 has moved far enough to engage the rod 121, the shock being cushioned by the spring 122, and has begun to move the carriage 33 to the left toward the pickup assembly 31. The carriage return member 114 has also closed the microswitch 126, thereby doing two things: (1) energizing the solenoid 62 to open the valve port 64 and move the wireadvancing rollers 35 and 36 on their carriage 40 in to advance the end 39 of the wire W out of the eye 75; (2) energizing the solenoid 233 to open the port 234 and move the piston 222, rod 223, and cross-head 224, to the right, thereby projecting the mandrel 32 out and through the eye 75.

The movement of the carriage return member 114 continues through Fig. 20, moving the carriage 33 and the entire wire-feeding assembly A up to the position where the spring S is begun. The spring 122 acts to momentarily hold the carriage 33 in position for the pickup 31 to catch and begin turning the spring S; it is a momentary reactive force. The book 215 catches the end 39 of the wire W and winds it around the mandrel 32. The continuation of winding (by the spindle 32) winds the spring S, pulling wire through the eye 75 and rollers 35, 36, while the pressure of the wire W against the face 86 of the V- notch member 71 will gradually move the carriage 33 back away from thepickup assembly 31. To make this movement possible, the carriage return member 114 closes the normally-open microswitch 127,-energizing the solenoid '132. The valve member 131 is moved to the right,

12 the port 133 opened, and air moves the piston 111 and the carriage return member 114 sharply to the right. The switch 126 is re-energized during passage of the member 114 to'the right, but nothing happens because the piston 222 is already in its retracted position where it was moved by the previous momentary closing of the switch 126.

This brings us to Fig. 21. The spring S continues to be wound, the cross-head 224 holding the switch 260 open so that accidental tripping of the switch 261 could not rcenergize the solenoid 135. The carriage 33 is free to move back under pressure of the wire W against the surface 86.

At the outer end of its stroke, the carriage return member 114 is stopped by the stop 117, and it closes the normally open microswitch 125. This energizes the sole noid 61, opening the valve port 65 and moving the carriage 40 out away from the eye 75 where it remains as the spring S is wound still more in Fig. 22. During this time the cam 160 guides the steadying member 150 in toward the mandrel 32, so that its V-notched block engages the spring S and helps hold the mandrel 32 steady in between the pickup assembly 31 and the eye assembly 34.

Then, between Figs. 22 and 17, the spring S reaches the end of the mandrel 32 and the wire W is broken off. At this time, the carriage 33 closes the normally open microswitch 141, which in turn energizes the time-delay switch 220. After a brief lapse of time to insure breakage of the wire W, the time-delay switch 220 energizes the solenoid 232 to retract the mandrel 32 and move the cross-head 224 to the right. Thus a new cycle begins.

The tension of the spring S is determined (1) by the pressure of the two rollers 35, 36 against each other, this being adjusted by turning the thumbscrew 45 to adjust the pressure of the spring 47; and (2) by the rotational position of the frame 50, this being adjusted by turning the screw 94 to project the bumper against the frame 50 and in opposition to the pressure of the spring 98.

When the wire diameter remains the same, the spring diameter is changed by putting in a new mandrel 32 of the proper diameter, a new mandrel guide 204, and a new eye block 70, and by adjusting the spacing of the blocks 71 and 73 and the spacing of the mandrel-support member 203 and hook assembly 210.

The length of the spring S is determined by the amount which the mandrel 32 projects beyond its chuck 247. When the mandrel length is changed, the handle 268 is used to adjust the microswitches 261 and 262 to the proper position for engagement by the cross-head 224. The microswitch 141 is also adjusted to be engaged by the carriage-borne member at the proper time.

When the wire diameter is to be changed, a new reel R of wire is installed and a new eye block 70 is installed. When the wire is of markedly different diameter, the block 67 is changed. Adjustments otherwise remain the same.

The machine operates very fast, preferably at about 7300 R. P. M. and can wind 10-20 springs per minute. It is fully automatic during operation and requires little care.

To those skilled in the art to which this invention relates, many additional changes in construction and widely differeing embodiments and applications of the invention will suggest themselves without departing from the spirit and scope of the invention as defined in the claims.

What is claimed is:

l. A spring-winding machine for automatically winding a helical spring from spring wire, including in combination: rotating wire pickup means; a mandrel mounted for reciprocation coaxially with respect to said pickup means; a carriage mounted for movement toward and away from said pickup means; carriage-return means for engaging said carriage and moving it toward said pickup means, and then disengagingit and moving away from it; wire-feeding means supported by said carriage for'presenting an end ofsaid wire to said pickup means whereby, when said carriage is closely adjacent said pickup means, said wire is seized by said rotating pickup means and wrapped around said mandrel to form said spring, said carriage being forced away from said pickup means by the pressure of the wire on said feeding means, as said spring is wound; and means for retracting said mandrel within said pickup means when the end of the wire is broken by being wound beyond the end of said mandrel and for projecting said mandrel out from said pickup means after the completed spring has dropped out of the way.

2. The machine of claim 1 wherein said wire-feeding means includes an eye block having a U-notch at one end; a V-notched bearing plate with its V-notch in general alignment with but shallower than said U-notch, the V engaging said mandrel, a bearing face portion adjacent said V engaged by said wire to transmit the pressure of said wire to said carriage, for moving said carriage away from said wire pickup means; and a concavely faced turning guide member directly opposite said U-notch for turning said wire out toward said wire pickup means.

3. A spring-winding machine for automatically winding a helical spring from spring wire, includingin combination: a rotating hook; a mandrel mounted along the axis of rotation of said hook and reciprocatable out beyond said hook and back in through said hook; a carriage mounted for movement toward and away from said hook, generally parallel to the axis of rotation thereof; wire-feeding means supported by said carriage for presenting an end of said wire to said hook when said carriage is closely adjacent said hook so that said wire will be seized by said rotating hook and wound around said mandrel; means supported by said carriage, againstwhich the wound wire bears for pushing said carriage away from said pickup means as said spring is wound; means for pulling said mandrel back in through said hook when the end of the wire is broken by being wound beyond the end of said mandrel, so that the completed spring falls out of the way; means for thereafter projecting said mandrel out beyond said hook; and means for moving said carriage toward said hook to the wire seizing position.

4. The machine of claim 3 wherein said wire-feeding means includes an eye block having a U-notch at one end, the U lying on its side, and a feeding groove in one face extending tangentially to one arm of said U; a V- notched bearing plate with a bearing face in engagement with the grooved face of said eye block and with its V-notch in general alignment with but shallower than said U-notch, the V engaging said mandrel, and the hearing face portion adjacent said V constituting said means supported by said carriage and being engaged by said wire to transmit the pressure of said wire to said carriage, for moving said carriage away from said hook; a mandrelsteadying V-notched block with its V facing in the opposite direction from the V of said plate to engage and steady the mandrel from the opposite side; and a con cavely faced turning guide member directly opposite said U-notch for turning said wire out toward said hook, said groove lying generally transverse to said mandrel.

' 5. A spring-winding machine for automatically winding a helical spring from spring wire, including in combination: rotating wire pickup means; a mandrel mounted for rotation with and reciprocation coaxially with respect to said pickup means; a carriage movable toward and away from said pickup means; carriage-return means for engaging said carriage in an outer position and moving it toward said pickup means, and then disengaging it and moving away from it; wire-feeding means supported by said carriage for projecting an end of said wire so that, when said carriage is closely adjacent said pickup means, said wire is seized by said rotating pickup means and wrapped around said mandrel to form said spring while being pulled through said wire-feeding means, said carriage being forced away from said pickup means by the pressure of the Wire against a portion of said carriage as said spring is wound; and means for retracting-said mandrel within said pickup means when the end of the wire is broken by being wound beyond the end of said mandrel and for projecting said mandrel out from said pickup means after the completed spring has dropped out of the way.

6. The machine of claim 5 wherein wire-advancing means are provided for advancing a predetermined short length of wire through said wire-feeding means for engagement by said wire pickup means, said wire advancing means comprising a pair of rollers between which said wire passes and means for moving said rollers transversely of their axes toward said wire pickup means.

7. The machine of claim 5 wherein the wire-feeding means includes an eye to direct said wire toward said wire pickup means and a pair of rollers between which said wire passes to said eye, said rollers having surfaces engaging said wire tightly to give tension as a result of pulling the wire through them during winding of the spring.

8. The machine of claim 7 wherein said rollers are mounted on a carriage bar that is reciprocatable toward and away from said eyeand wherein there are means for moving said carriage bar between two positions, for advancing a length of wire toward said eye.

9. The machine of claim 8 wherein the wire-engaging surface of one said roller is grooved to receive part of said wire and the other said roller has a roughened wireengaging surface.

10. The machine of claim 9 wherein said other roller is rotatably supported on a pivotally supported arm and wherein there is means for exerting pressure on said arm for tightening said rollers together.

11. The machine of claim 8 wherein said means for moving said carriage bar comprisesa pneumatic cylinder supported on said carriage.

12. The machine of claim 8 wherein said wire-feeding means is pivotally mounted'on said carriage and whereby means are provided for regulating the rotational position thereof, thereby exerting tension on said wire at said mandrel.

13. A spring-winding machine for automatically winding a helical spring from spring wire, including in combination: a rotating hook; a mandrel mounted along the axis of rotation of said hook; mandrel translating means for advancing said mandrel out beyond said hook and for withdrawing it back through said hook; a carriage mounted for movement toward and away from said hook, generally parallel to the axis of rotation thereof; wirefeeding means supported by said carriage for presenting an end of said wire to said hook when said carriage is closely adjacent said hook so that said wire will be seized by said rotating hook and wound around said mandrel; means supported by said carriage, against which the wound wire bears for pushing said carriage away from said pickup means as said spring is wound; said mandrel translating means being actuated to withdraw said mandrel when the end of the wire is broken by being wound beyond the end of said mandrel and then, after an interval, to advance said mandrel.

14. The machine of claim 13 wherein said carriage supports a tubular mandrel-end-steadying device that receives said mandrel on the opposite side of said wire feeding means from said hook.

- 15. The machine of claim 13 wherein said carriage return means comprises a pneumatic cylinder having a piston with an extended piston rod having carriageengaging means on its outer end.

16. The machine of claim 15 wherein said carriage engaging means engages means at the inner limit of its travel toward said hook that automatically actuates said pneumatic cylinder to move said piston rod in the opposite direction away from said carriage.

17. The machine of claim 15 wherein on its travel

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