Coil spring forming and conveying assembly

Information

  • Patent Grant
  • 6430982
  • Patent Number
    6,430,982
  • Date Filed
    Wednesday, January 3, 2001
    23 years ago
  • Date Issued
    Tuesday, August 13, 2002
    22 years ago
Abstract
Disclosed herein is a coil spring forming head which is periodically operative to at least partially form coil springs having a plurality of coils and which includes a wire feed advancing mechanism operative to feed the wire which is formed into coil springs, a pitch control mechanism operative to control the diameter of the coils of the coil springs being formed, a diameter control mechanism operative to control the pitch of the coils of the coil springs being formed, and a control including a storage area containing instructions for operation of the wire feed advancing mechanism, the pitch control mechanism, and the diameter control mechanism, a wire feed controller connected to the wire feed advancing mechanism to control operation thereof, a pitch controller connected to the pitch control mechanism to control operation thereof, a diameter controller connected the diameter control mechanism to control operation thereof, and a programmable switching device connected to the wire feed controller, to the pitch controller, and to the diameter controller and selectively connectable to the storage area to afford forwarding of selected instructions from the storage area to the wire feed controller, to the pitch controller, and to the diameter controller.
Description




BACKGROUND OF THE INVENTION




The invention relates generally to machines for forming coil springs and delivering such coil springs to a coil spring assembling machine in which the coil springs are laced or otherwise connected together to form a coil spring assembly. In such combined machinery, a coil spring forming machine individually delivers the formed coiled springs to a transfer conveyor which, in turn, delivers the coil springs to a transfer apparatus which, in turn, delivers the coil springs to the coil spring assembling machine to form the coil spring assembly.




Attention is directed to the following U.S. Patents:




U.S. Pat. No. 4,014,371 (Walker) issued Mar. 29, 1977




U.S. Pat. No. 4,413,659 (Zangerle) issued Nov. 8, 1983




U.S. Pat. No. 4,492,298 (Zapletal et al.) issued Jan. 8, 1985




U.S. Pat. No. 5,477,893 (Wentzek et al.) issued Dec. 26, 1995




U.S. Pat. No. 5,579,810 (Ramsey et al.) issued Dec. 3, 1996




Attention is also directed to a prior brochure which is entitled “Announcing the World's Fastest, Most Advanced Pocket Spring Technology” and which was circulated by Elfex International Limited of Pickering, Ontario LlW1Z9 Canada.




SUMMARY OF THE INVENTION




The invention provides a coil spring forming machine and transfer conveyor assembly comprising a transfer conveyor operable through a succession of operational cycles and including an endless conveyor assembly arranged for periodic travel along a predetermined path and through a coil spring loading station, and a conveyor driving device drivingly connected to the conveyor assembly and operative, upon each energization thereof, to drive the conveyor assembly through one operational cycle thereof, a first coil spring forming machine located adjacent the predetermined path, operable through a succession of operational cycles to form coil springs, and, during a period of non-movement of the conveyor assembly, to load a coil spring on the conveyor assembly at the loading station, and including a first coil spring forming driving device operative, upon each energization thereof, to drive the first coil spring forming machine through one operational cycle thereof, a second coil spring forming machine located adjacent the predetermined path, operable through a succession of operational cycles to form coil springs, and, during a period of non-movement of the conveyor assembly, to load a coil spring on the conveyor assembly at the loading station, and including a second coil spring forming driving device operative, upon each energization thereof, to cause actuation of the second coil spring forming machine through one operational cycle thereof, and a control system operative to cause energization of the conveyor driving device in response to completion of one operational cycle of one of the first and second coil spring forming driving devices, and operative to cause energization of one of the first and second coil spring forming driving devices in response to completion of one operational cycle of the conveyor driving device.




The invention also provides a coil spring forming machine and transfer conveyor assembly comprising a transfer conveyor operable through a succession of operational cycles and including an endless conveyor assembly arranged for periodic travel along a predetermined path and for passage through a coil spring loading station, and a conveyor driving device drivingly connected to the conveyor assembly and operative, upon each energization thereof, to drive the conveyor assembly through one operational cycle thereof, a first coil spring forming machine located on one side of the predetermined path, operable through a succession of operational cycles to form a first coil spring, and, during a period of non-movement of the conveyor assembly, to load the first coil spring on the conveyor assembly in the loading station, and including a first coil spring forming driving device operative, upon each energization thereof, to drive the first coil spring forming machine through one operational cycle thereof, and a second coil spring forming machine located on the other side of the predetermined path, operable through a succession of operational cycles to form a second coil spring, and, during a period of non-movement of the conveyor assembly, to load the second coil spring on the conveyor assembly in the loading station, and including a second coil spring forming driving device operative, upon each energization thereof, to drive the second coil spring forming machine through one operational cycle thereof, and a control system operative to cause energization of the conveyor driving device through one operational cycle in response to completion of one operational cycle of both of the first and second coil spring forming driving devices, and operative to cause simultaneous energization of the first and second coil spring forming driving devices in response to completion of one operational cycle of the conveyor driving device.




The invention also provides a coil spring forming machine and transfer conveyor assembly comprising a transfer conveyor operable through a succession of operational cycles and including an endless conveyor assembly arranged for periodic travel along a predetermined path and for passage through a coil spring loading station, and a conveyor driving device drivingly connected to the conveyor assembly and operative, upon each energization thereof, to drive the conveyor assembly through one operational cycle thereof, a first coil spring forming machine located on one side of the predetermined path, operable through a succession of operational cycles to form a first coil spring, and, when one of the pallets is in the loading station and during a period of non-movement of the conveyor assembly, to load the first coil spring on the conveyor assembly in the loading station, and including a first coil spring forming driving device operative, upon each energization thereof, to drive the first coil spring forming machine through one operational cycle thereof, a second coil spring forming machine located on the other side of the predetermined path, operable through a succession of operational cycles to form a second coil spring, and, when the one pallet is in the loading station and during a period of non-movement of the conveyor assembly, to load the second coil spring on the conveyor assembly in the loading station, and including a second coil spring forming driving device operative, upon each energization thereof, to drive the second coil spring forming machine through one operational cycle thereof, and a control system operative to cause energization of the conveyor driving device through a first operational cycle in response to completion of one operational cycle of the first coil spring forming driving device, operative to cause energization of the second coil spring forming driving device in response to completion of the first operational cycle of the conveyor driving device, operative to cause energization of the conveyor driving device through a second operational cycle in response to completion of one operational cycle of the second coil spring forming driving device, and operative to cause energization of the first coil spring forming driving device in response to completion of the second operational cycle of the conveyor driving device.




The invention also provides a coil spring forming machine and transfer conveyor assembly comprising a transfer conveyor operable through a succession of operational cycles and including an endless conveyor assembly arranged for periodic travel along a predetermined path and through a coil spring loading station, and a conveyor driving device drivingly connected to the conveyor assembly and operative, upon each energization thereof, to drive the conveyor assembly through one operational cycle thereof, a coil spring forming machine located adjacent the predetermined path, operable through a succession of operational cycles to form a first coil spring, and, during a period of non-movement of the conveyor assembly, to load the first coil spring on the transfer conveyor, and including a coil spring forming driving device operative, upon each energization thereof, to drive the coil spring forming machine through one operational cycle thereof, and a control system operative to cause energization of the conveyor driving device in response to completion of one operational cycle of the coil spring forming driving device, and, thereafter, operative to cause energization of the coil spring forming driving device in response to completion of one operational cycle of the conveyor driving device.




The invention also provides a coil spring forming machine and transfer conveyor assembly comprising a transfer conveyor operable through a succession of operational cycles and including an endless conveyor assembly arranged for periodic travel along a predetermined path and through a coil spring loading station, and a conveyor driving device drivingly connected to the conveyor assembly and operative, upon each energization thereof, to drive the conveyor assembly through one operational cycle thereof, a first coil spring forming machine located adjacent the predetermined path, operable through a succession of operational cycles to form coil springs, and, during a period of non-movement of the conveyor assembly, to load a coil spring on the transfer conveyor, and including a first coil spring forming driving device operative, upon each energization thereof, to drive the first coil spring forming machine through one operational cycle thereof, a second coil spring forming machine located adjacent the predetermined path, operable through a succession of operational cycles to form coil springs, and, during a period of non-movement of the conveyor assembly, to load a coil spring on the transfer conveyor, and including a second coil spring forming driving device operative, upon each energization thereof, to drive the second coil spring forming machine through one operational cycle thereof, and a control system including first and second counting and switching devices which are respectively connected to one of (a) the conveyor driving device, and (b) the first and second coil spring forming driving devices, and which are respectively connectable to and disconnectable from the other of (a) the conveyor driving device, and (b) the first and second coil spring forming driving devices, the first counting and switching device being adjustable to select a desired number of successive operational cycles of the first coil spring forming machine, being operable to effect the selected desired number of successive operational cycles of the first coil spring forming machine by successive energization of the first coil spring forming driving device in response to each successive completion of the selected desired number of operational cycles of the conveyor driving device, and being operable, upon completion of the selected desired number of operational cycles of the conveyor driving device, to cause disconnection of the conveyor driving device and the first counting and switching device and connection of the conveyor driving device and the second counting and switching device, and the second counting and switching device being adjustable to select a desired number of successive operational cycles of the second coil spring forming machine, being operable to effect the selected desired number of successive operational cycles of the second coil spring forming machine by successive energization of the second coil spring forming driving device in response to each successive completion of the selected desired number of operational cycles of the conveyor driving device, and being operable, upon completion of the selected desired number of operational cycles of the conveyor driving device, to cause disconnection of the conveyor driving device and the second counting and switching device and connection of the conveyor driving device and the first counting and switching device.




The invention also provides a coil spring forming head which is periodically operative to at least partially form coil springs and which includes a wire feed advancing mechanism, a wire feed driving device drivingly connected to said wire feed advancing mechanism, a pitch control tool, a pitch control driving device drivingly connected to said pitch control tool and being operative in response to operation of said wire feed driving device, a diameter control tool, and a diameter control driving device drivingly connected to said diameter control tool and being operative in response to operation of said wire feed driving device.




The invention also provides a coil spring forming head which is periodically operative to at least partially form coil springs and which includes a wire feed advancing mechanism, a wire feed driving servo-motor drivingly connected to said wire feed advancing mechanism, a pitch control tool, a pitch control driving servo-motor drivingly connected to said pitch control tool and being operative in response to operation of said wire feed driving device, a diameter control tool, and a diameter control driving servo-motor drivingly connected to said diameter control tool and being operative in response to operation of said wire feed driving device.




The invention also provides a coil spring forming head which is periodically operative to at least partially form coil springs having a plurality of coils and which includes a wire feed advancing mechanism operative to feed the wire which is formed into coil springs, a pitch control mechanism operative to control the pitch of the coils of the coil springs being formed, a diameter control mechanism operative to control the diameter of the coils of the coil springs being formed, and a control including a storage area containing instructions for operation of said wire feed advancing mechanism, said pitch control mechanism, and said diameter control mechanism, a wire feed controller connected to said wire feed advancing mechanism to control operation thereof, a pitch controller connected to said pitch control mechanism to control operation thereof, a diameter controller connected said diameter control mechanism to control operation thereof, and a programmable switching device connected to said wire feed controller, to said pitch controller, and to said diameter controller and selectively connectable to said storage area to afford forwarding of selected instructions from said storage area to said wire feed controller, to said pitch controller, and to said diameter controller.




The invention also provides a coil spring forming head which is periodically operative to at least partially form coil springs having a plurality of coils and which includes a wire feed advancing device, a wire feed driving device drivingly connected to said wire feed advancing device and operative to feed the wire to be formed into coil springs, a pitch control tool, a pitch control driving device drivingly connected to said pitch control tool and being operative, in response to operation of said wire feed driving device, to control the pitch of the coils of the coil springs being formed, a diameter control tool, a diameter control driving device drivingly connected to said diameter control tool and being operative, in response to operation of said wire feed driving device, to control the diameter of the coils of the coil springs being formed, and a control including a storage area containing instructions for operation of said wire feed driving device, said pitch control driving device, and said diameter control driving device, a wire feed controller connected to said wire feed driving device to control operation thereof, a pitch controller connected to said pitch control driving device to control operation thereof, a diameter controller connected said diameter control driving device to control operation thereof, and a programmable switching device connected to said wire feed controller, to said pitch controller, and to said diameter controller and selectively connectable to said storage area to afford forwarding of selected instructions from said storage area to said wire feed controller, to said pitch controller, and to said diameter controller.




The invention also provides a coil spring forming head which is periodically operative to at least partially form coil springs having a plurality of coils and which includes a wire feed advancing device, a wire feed driving servo-motor drivingly connected to said wire feed advancing device and operative to feed the wire to be formed into coil springs, a pitch control tool, a pitch control driving servo-motor drivingly connected to said pitch control tool and being operative, in response to operation of said wire feed driving servo-motor, to control the pitch of the coils of the coil springs being formed, a diameter control tool, a diameter control driving servo-motor drivingly connected to said diameter control tool and being operative, in response to operation of said wire feed driving servo-motor, to control the diameter of the coils of the coil springs being formed, and a control including a storage area containing instructions for operation of said wire feed driving servo-motor, said pitch control driving servo-motor, and said diameter control driving servo-motor, a wire feed controller connected to said wire feed driving servo-motor to control operation thereof, a pitch controller connected to said pitch control driving servo-motor to control operation thereof, a diameter control controller connected said diameter control driving servo-motor to control operation thereof, and a programmable switching device connected to said wire feed controller, to said pitch controller, and to said diameter control controller and selectively connectable to said storage area to afford forwarding of selected instructions from said storage area to said wire feed controller, to said pitch controller, and to said diameter control controller. Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings. dr




DESCRIPTION OF THE DRAWINGS





FIG. 1

is a schematic view of a coil spring forming and assembling machine which embodies various of the features of the invention.





FIG. 2

is a fragmentary end elevational view of one embodiment of a portion of the coil spring forming and assembling machine shown in FIG.


1


.





FIG. 3

is an elevational view taken along line


3





3


of FIG.


2


.





FIG. 4

is a plan view of the undersurface of one of the pallets included in the construction shown in FIG.


3


.





FIG. 5

is an enlarged perspective view of the pallet shown in

FIG. 4

with a coil spring located thereon when the pallet is in the coil spring loading station.





FIG. 6

is a top plan schematic view of a portion of a second embodiment of a coil spring forming and assembling machine which embodies various of the features of the invention.





FIG. 7

is an elevational view taken along line


7





7


of FIG.


6


.





FIG. 8

is a side elevational view of one of the pallets included in the construction shown in FIG.


7


.





FIG. 9

is a top plan view of the pallet shown in FIG.


8


.





FIG. 10

is an enlarged perspective view of the pallet shown in

FIGS. 8 and 9

with a coil spring located thereon when the pallet is in the coil spring loading station.





FIG. 11

is an enlarged view of one of the coil spring forming machines included in the coil spring forming and assembling machine shown in FIG.


1


.





FIG. 12

is an exploded view of a wire feed advancing mechanism included in the coil spring forming and assembling machine shown in FIG.


11


.





FIG. 13

is an exploded view of a pitch control mechanism included in the coil spring forming and assembling machine shown in FIG.


11


.





FIG. 14

is an exploded view of a diameter control mechanism included in the coil spring forming and assembling machine shown in FIG.


11


.





FIG. 15

is a schematic view of another embodiment of a coil spring forming and assembling machine which embodies various of the features of the invention.





FIG. 16

is a diagrammatic view of one embodiment of a control system incorporated in the machine assembly shown in FIG.


2


.





FIG. 17

is a diagrammatic view of a second embodiment of a control system incorporated in the machine assembly shown in FIG.


2


.





FIG. 18

is a diagrammatic view of one embodiment of a control system incorporated in the machine assembly shown in FIG.


6


.





FIG. 19

is a diagrammatic view of one embodiment of a control incorporated in the coil spring forming machines shown in FIG.


2


.





FIG. 20

is an enlarged side elevational view of the delivery mechanism incorporated in the coil spring forming machines included in the coil spring forming and assembling machine shown in FIG.


2


.





FIG. 21

is an enlarged plan view of the delivery mechanism shown in FIG.


20


.





FIG. 22

is a view, partially in section, taken along line


22





22


of FIG.


20


.





FIG. 23

is a view taken along line


23





23


of FIG.


20


.





FIG. 24

is a fragmentary view of a portion of the delivery mechanism shown in FIG.


20


.











Before one embodiment of the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of the construction and the arrangements of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.




GENERAL DESCRIPTION OF THE INVENTION




Shown schematically in

FIG. 1

of the drawings is a coil spring forming and assembling machine


111


including first and second coil spring forming machines


113


and


115


which form and deliver coil springs to a single, incrementally advancing transfer conveyor


121


which, in turn, delivers the coil springs to a coil spring transfer apparatus


125


which, in turn, delivers the coil springs to a coil spring assembly apparatus


131


which assembles the coil springs into a coil spring assembly.




The first and second coil spring forming machines


113


and


115


and the transfer conveyor


121


comprise an integrated coil spring forming machine and transfer conveyor assembly


141


in which the first and second coil spring forming machines


113


and


115


are respectively located on opposite sides of the transfer conveyor


121


for operation to simultaneously or alternately directly deliver fully formed (and tempered) coil springs to the single transfer conveyor


121


. The coil spring forming and assembling machine


111


also includes a control system


135


in which operation of the coil spring forming machine(s)


113


and


115


are dependent on completion of the incremental advancement of the transfer conveyor


121


, and in which operation of the transfer conveyor


121


is dependent on completion, and delivery, of a fully completed coil spring by one or both of the coil spring forming machine(s)


113


and


115


.




More particularly, the transfer conveyor


121


includes (see

FIG. 3

) an endless conveyor chain or assembly


151


arranged for periodic or incremental travel along a predetermined path and through a coil spring loading station


153


, and a (schematically illustrated) servo-operated driving motor or other device


155


which is suitably mounted on the transfer conveyor


121


and which is operatively connected to the transfer conveyor chain or assembly


151


for periodically or incrementally driving the transfer conveyor chain or assembly


151


on the predetermined path and through a series of incremental advances which are all of the same length. Any suitable servo-operated driving device, including a linear servo-motor, can be employed and, in the disclosed construction, a commercially available conveyor drive servo-motor


155


is employed.




The endless conveyor chain or assembly


151


includes a series of pivotally connected pallets


161


which are successively located in the loading station


153


incident to periodic or incremental travel of the transfer conveyor chain or assembly


151


on the predetermined path.




The pallets


161


can take various forms. In one embodiment shown in

FIGS. 4 and 5

, the pallets


161


are of generally identical construction, have a generally flat outer surface


162


adapted to receive one of the terminal end coils of a coil spring, and are generally rectangular in shape, having a length which, in the direction of travel of the transfer conveyor


121


, is substantially equal to or slightly more than the major or largest diameter of two coil springs standing side-by-side. Each pallet


161


also includes one or more magnets


163


which are operative to hold the coil springs in place on the pallets


161


during advancement of the transfer conveyor


121


. More particularly, in the specifically disclosed construction, each pallet


161


includes, on the outer surface thereof, a plurality of permanent magnets


163


. Any suitable magnet construction can be employed.




Thus, as shown in

FIG. 5

, the bottom terminal convolution of the coil springs are magnetically held by the pallets


161


and the upper terminal convolutions thereof come into engagement (see

FIG. 3

) with a stationary compression bar


164


as the transfer conveyor


121


advances the coil springs away from the loading station


153


.




The pallets


161


can be directly pivotally connected to each other or, alternatively, the pallets is


161


can be suitably mounted on, or carried by, a commercial chain. In the specific construction shown in

FIG. 3

, the pallets are mounted on a commercially obtainable chain.




Shown in

FIGS. 8

,


9


, and


10


, is another pallet construction in which each of the pallets


161


includes a lower generally rectangular base web


165


which has a lower generally flat surface. At one longitudinal end thereof, each of the pallets


161


includes a central ear


166


having a transverse bore adapted to accept a hinge pin (not shown) of suitable construction. At the other longitudinal end thereof, each of the pallets


161


includes a pair of transversely spaced ears


168


which receive therebetween the central ear


166


of an adjacent one of the pallets


161


and which include respective bores adapted to receive the just-mentioned hinge pin located in the central ear


166


of the adjacent one of the pallets


161


.




The pallets


161


shown in

FIGS. 8

,


9


, and


10


also include, adjacent each end, respective tabs


169


which extend toward each other in spaced relation to the base web


165


and which, in cooperation with the base web


165


, define sockets or pockets


170


which are open on each side so to accommodate loading of the pallets


161


with coil springs from either side. The tab


169


at the other end, i.e., the end having the spaced ears


168


, also includes, adjacent each of the sides, respective upwardly extending generally triangular wing portions


171


. Accordingly, during coil spring loading, the pallet


161


is arranged to laterally receive one end coil or convolution of each coil spring to be transported. In this regard, the wing portions


171


accommodate the initial axial curve of the wire from the end coil.




In addition, the transfer conveyor


121


also includes a drive wheel or pulley


173


which is periodically and incrementally driven about a horizontal axis and relative to the coil spring loading station


153


by the conveyor drive servo-motor


155


, and a wheel member or pulley (not shown) which is spaced from the drive wheel


173


and which is periodically and incrementally rotatably moveable about a fixed horizontal axis. The endless transfer conveyor chain or assembly


151


is partially trained around the drive wheel


173


and the wheel member for periodic and incremental travel along the predetermined path and through the coil spring loading station


153


.




In operation, the pallets


161


are successively located in the loading station


153


incident to incremental travel or advancement of the transfer conveyor chain or assembly


151


on the predetermined path, with each such incremental advance occurring in response to each energization of the conveyor drive servo-motor


155


and being of the same length. Consequently, each incremental advance of the transfer conveyor chain or assembly


151


is approximately the length of the pallets


161


. While the endless conveyor chain or assembly


151


is disclosed above as being periodically and incrementally advanced by the drive wheel


173


which, in turn, is driven by the conveyor drive servo-motor


155


, if desired, the wheel member (not shown) could be driven by the conveyor drive servo-motor


155


instead of the drive wheel or pulley


173


or any other arrangement could be employed for incrementally advancing the transfer conveyor chain or assembly


151


incident to each energization of the conveyor drive servo-motor


155


.




The first coil spring forming machine


113


includes (as shown in

FIG. 2

) a (schematically illustrated) servo-operated main forming machine driving motor or other device


225


which is suitably mounted on the first coil spring forming machine


113


and which is operative, upon each energization thereof, to cause actuation of the first coil spring forming machine


113


through one operational cycle thereof. Any suitable servo-operated driving device, including a linear servo-motor, can be employed and, in the disclosed construction, a first commercially available main forming machine drive servo-motor


225


is employed.




The servo-operated main forming machine drive device


225


controls energization of a wire feed advancing mechanism


231


(see FIG.


12


), a pitch control mechanism


235


(see FIG.


13


), and a diameter control mechanism


243


(see FIG.


14


), (all still to be described) and specifically drives or powers a spoke assembly


291


and a delivery mechanism or conveyor


321


(all still to be described), all of which are part of the coil spring forming machine


113


.




The first coil spring forming machine


113


also includes a first coil spring forming head


201


which is periodically operative to successively at least partially form coil springs.




In addition, the first coil spring forming machine


113


operates, when one of the pallets


161


is in the loading station


153


and during a period of non-movement of the conveyor chain or assembly


151


, to deliver or load a fully or completed formed (and tempered) coil spring on the one of the pallets


161


located in the loading station


153


.




Except for being located on the opposite side of the transfer conveyor


121


from the first coil forming machine


113


and except for preferably being of the opposite hand, i.e., being left-handed instead of being right-handed, the second coil spring forming machine


115


is generally of identical construction to the first coil spring forming machine


113


, could be of the same hand, and includes a (schematically illustrated) second servo-operated main forming machine driving motor or other device


226


which is suitably mounted on the second coil spring forming machine


115


and which is operative, upon each energization thereof, to cause actuation of the second coil spring forming machine


115


through one operational cycle thereof. Any suitable servo-operated driving device, including a linear servo-motor, can be employed and, in the disclosed construction, a second commercially available main forming machine drive servo-motor (


226


) is employed.




The second main forming machine drive servo-motor


226


controls energization (with respect to the second coil spring forming machine


115


) of a wire feed advancing mechanism


231


, a pitch control mechanism


235


, and a diameter control mechanism


243


, (all still to be described) and specifically drives or powers a spoke assembly


291


and a delivery mechanism or conveyor


321


(all still to be described), all of which are part of the coil spring forming machine


115


.




In addition, the second coil spring forming machine


115


also includes a second coil spring forming head


211


which is periodically operative to successively at least partially form coil springs. Still further in addition, the second coil spring forming head


211


operates, when the one of the pallets


161


is in the loading station


153


and during a period of non-movement of the conveyor chain or assembly


151


, to load a fully or completely formed (and tempered) coil spring on the one of the pallets


161


located in the loading station


153


.




In an alternative embodiment, as will be disclosed, the second coil forming machine


115


can be operative to periodically form coil spring and, when the next one of the pallets


161


is in the loading station


153


and during the next period of non-movement of the conveyor chain or assembly


151


, to load a completed or fully formed (and tempered) coil spring on the next one of the pallets


161


.




Because the first and second coil spring forming machines


113


and


115


are generally identically constructed, only the first coil spring forming machine


113


will be further described. In this regard, the first servo-operated main forming machine drive motor or other device


225


(and the second servo-operated main forming machine drive motor


226


) can take any suitable form, including a linear servo-motor, and in the disclosed construction, is preferably in the form of a commercially available servo-motor which is suitably mounted on the associated one of the coil spring forming machines


113


and


115


.




Because the first and second coil spring forming heads


201


and


211


are also of the same construction, except for being left- and right-handed, only the coil spring forming head


201


will be described. In this regard, the coil spring forming head


201


, as shown best in

FIGS. 2 and 11

through


14


, is operative successively to at least partially form a series of generally identical coil springs which can be either knotted or unknotted coil, and includes a frame


221


including a generally vertically extending frame member


223


.




Further in this regard, the wire feed advancing mechanism


231


incorporated in the first coil spring forming head


201


(see

FIG. 12

) includes and is driven by a servo-operated driving motor or other device


232


which is suitably mounted in the frame


221


and which is operative or energized in response to operation of the main forming machine drive servo-motor


225


(or


226


). The servo-operated driving motor or other device


232


can take any suitable form, including a linear servo-motor, and in the disclosed construction, is preferably in the form of a commercially available wire feed servo-motor (


232


).




In addition, the pitch control mechanism


233


incorporated in the first coil spring forming head


201


includes (see

FIG. 13

) a pitch control tool


235


and a servo-operated driving motor or other device


239


which is suitably mounted on the frame


221


, which is drivingly connected to the pitch control tool


235


, and which is operative, in response to each operation of the wire feed servo driving motor or other device


232


, to drive or locate the pitch control tool


235


. The just-mentioned pitch control servo-operated driving motor or other device


239


can take any suitable form, including a linear servo-motor, and in the disclosed construction, is preferably in the form of a commercially available pitch control servo-motor


239


.




Still further in addition, the diameter control mechanism


243


incorporated in the first coil spring forming head


201


includes (see

FIG. 14

) a diameter control tool


245


and a servo-operated driving motor or other device


249


which is suitably mounted on the frame


221


, which is drivingly connected to the diameter control tool


245


, and which is operative, in response to each operation of the wire feed servo-motor


232


, to drive or locate the diameter control tool


245


. The servo-operated driving motor or other device


249


can take any suitable form, including a linear servo-motor, and in the disclosed construction, is preferably in the form of a commercially available diameter control servo-motor (


249


).




The wire feed advancing mechanism


231


can be of any suitable construction and, in the specifically disclosed construction, the wire feed advancing mechanism


231


includes (see

FIGS. 11 and 12

) a pair of feed rollers


251


which are operative to incrementally advance a wire


250


from which the coil springs are formed. The feed rollers


251


are respectively mounted on a pair of drive shafts


253


which are respectively rotatably supported by bearings fixedly supported by the frame member


223


and which are respectively fixed to, and rotatably driven by, a pair of meshing gears


255


. One of the meshing gears


255


is rotatively driven by the wire feed drive servo-motor


232


which is fixedly mounted on the frame


221


.




The pitch control tool mechanism


233


, including the pitch control tool


235


, can also be of any suitable construction.




Various constructions can be employed to drivingly connect the pitch control tool


235


to the pitch control servo-motor


239


. In the preferred and specifically disclosed construction, (as shown in

FIG. 13

) the pitch control servo-motor


239


is fixedly mounted on the frame


221


and is connected by a suitable ballscrew mechanism


257


to an output member


259


so as to convert the rotary output of the pitch control servo-motor


239


into axial translatory movement of the output member


259


. As shown in the drawings, the output member


259


passes through a bearing supported in the frame member


223


and includes an outer end


261


having mounted thereon a pitch control tool holder


262


to which the pitch control tool


235


is fixed. The pitch control tool holder


262


and the pitch control tool


235


have common movement with the output member


259


incident to operation of the pitch control servo-motor


239


. The pitch control tool


235


engages the wire


250


during coil spring formation to effect the desired coil spring pitch.




The diameter control mechanism


243


, including the diameter control tool


245


, can also be of any suitable construction.




Various constructions can be employed to drivingly connect the diameter control tool


245


to the diameter control servo-motor


249


. In the preferred and specifically disclosed construction, (as shown in

FIGS. 11 and 14

) the diameter control servo-motor


249


is pivotally mounted on the frame


221


and is connected by a suitable ballscrew mechanism


263


to an output member


265


so as to convert the rotary output of the diameter control servo-motor


249


into axial translatory movement of the output member


265


. As shown in the drawings, at the outer end thereof, the output member


265


is pivotally connected to one end of a lever


267


which, at the other end thereof, is fixedly connected to a shaft member


269


which passes through a bearing fixedly supported by the frame member


223


and which, at the outer end thereof, includes a radially outwardly extending diameter control finger


271


which pivots about the axis of the shaft member


269


incident to axial translatory movement of the output member


265


driven by the diameter control servo-motor


249


. At the outer end thereof, the diameter control finger


271


includes the diameter control tool


245


which engages the wire


250


.




Both the pitch control servo-motor


239


and the diameter control servo-motor


249


are dependent upon, and are operated or energized in response to, energization of the wire feed servo-motor


232


. However, the operation of the pitch control servo-motor


239


and the diameter control servo-motor


249


can be varied by suitable controls in order to vary the pitch and diameter of the coil springs being formed. Notwithstanding, and to repeat, the pitch control servo-motor


239


and the diameter control servo-motor


249


operate only in response to, and during the operation of, the wire feed servo-motor


232


.




The coil spring forming machines


113


and


115


also respectively includes, as shown in

FIG. 19

, a control


275


permitting automatic variation of the physical parameters of the coil springs to be formed, manufactured, or produced. In other words, the control


275


can be employed to produce coil springs of the same or differing pitch and diameter in a single row of spring coils to be transferred from the transfer conveyor


121


to the coil spring transfer apparatus


125


.




More specifically in this regard, the control includes a memory or storage area


277


which can of any suitable construction and which is operative to store wire advancing, pitch, and diameter parameters or instructions for each of a number of physically different coil springs (


22


in the illustrated construction) which can be formed, produced or manufactured by the coil spring forming machines


113


and


115


.




In addition, the control


275


includes a wire feed controller


279


which controls the length of wire to be advanced for each coil spring, a pitch controller


281


which controls the pitch of the coils of the coil springs, and a diameter controller


283


which controls the diameter of the coils of the coil springs. The wire feed controller


279


, the pitch controller


281


, and the diameter controller


283


can be of any suitable construction, are respectively connected to the wire feed mechanism


231


, the pitch control mechanism


233


, and the diameter mechanism


243


. More specifically, the wire feed controller


279


, the pitch controller


281


, and the diameter controller


283


are respectively connected to the wire feed driving device


232


, the pitch control driving device


239


, and the diameter driving device


249


, and are, as indicated, operable to control the driving devices to obtain the desire length of feed wire, the desired pitch, and the desired diameter.




Still further in addition, the control


275


includes a programmable switching device


285


which can be of any suitable construction and which is operative to inform the wire feed controller


279


, the pitch controller


281


, and the pitch diameter controller


283


of the parameters of the coil springs to be formed or manufactured in accordance with a previously arranged or programmed coil spring sequence.




In operation, the operator initially inputs into the storage area


277


the parameters for


22


differing coil springs. The operator then inputs, into the programmable switching device


285


, a desired sequence or order of coil springs to be formed or manufactured. Thereafter, the programmable switching device


285


inputs into the wire feed controller


279


, the pitch controller


281


, and the pitch diameter controller


283


the information required to manufacture the first of the coil springs in the desired prearranged sequence or order. Thereafter, the pitch control driving device will be actuated, as already explained, to cause the wire feed advancing mechanism


231


, the pitch control mechanism


233


, and the pitch diameter control mechanism


243


to operate so that the coil spring forming machines


113


and


115


produce the desired coil springs. When the first of the coil springs in the desired sequence or order is formed or manufactured, the programmable switching device


285


will then input to the controllers


279


,


281


, and


283


the information for the formation or manufacture of the next coil spring in the prearranged sequence or order. The second coil spring in the prearranged sequence or order can be of the same construction as the first coil spring or can be of physically different construction. After formation or manufacture of all of the coil springs in the prearranged sequence or order to form a row of coil springs, the programmable switching device


285


then operates to commence the formation or manufacture of another prearranged series or sequence of coil springs.




Thus, the control


275


is operative, in response to each successive actuation of the coil spring forming machines


113


and


115


, to produce or form the same coil spring as previously manufactured, or to produce or form another coil spring, all in accordance with a previously programmed schedule or prearranged sequence or predetermined programmed series of coil springs of the same or differing parameters, which coil springs are directly delivered to or supplied to the transfer conveyor


121


.




The first coil forming machine


113


also includes (as shown in

FIG. 11

) a rotating spoke assembly


291


which is of known construction, which is rotatably mounted on the frame


221


, and which includes a hub


293


, and a plurality of spokes or arms


295


which extend from the hub


293


and which respectively include, at the outer end thereof, a releasable gripping mechanism


297


.




The spoke assembly


291


is incrementally rotatably driven by the main forming machine drive servo-motor


225


in such manner as to serially locate one of the spokes


295


and associated gripping mechanism


297


in position to grasp a partially formed coil spring as the partially formed coil spring exits the coil forming head


201


. Thereafter, the spoke assembly


291


incrementally rotates in response to each succeeding energization of the main forming machine drive servo-motor


225


so as to first move the gripped coil spring to a bending or other work station


301


. At the bending or other work station


301


, the axially spaced terminal coils or ends of the coil spring are further formed by suitable, schematically illustrated, wire forming mechanism(s)


303


which are of known construction and which are supported by the frame


221


at the bending or other work station


301


. The wire forming mechanism(s)


303


are utilized to further form the partially formed coil springs by performing such operations as bending, knotting, crimping, or any other further formation of the coil spring ends. The wire forming mechanism(s)


303


can be driven by any suitable arrangement, including a servo-operated drive motor(s) or other device(s) (not shown) which, preferably, can be in the form of a commercially available servo-motor(s) which is/are mounted on the frame


221


.




Thereafter, the spoke assembly


291


again incrementally rotates to move the gripped coil spring so as to serially deliver the partially formed coil spring to a transfer station


315


wherein the gripped coil spring is released and is contacted (see

FIG. 2

) by a delivery mechanism or conveyor


321


which is part of the first coil spring forming machine


113


, which is powered by the main forming machine drive servo-motor


225


, and which can be of any suitable construction.




In the construction shown in

FIG. 2

, the delivery mechanism or conveyor


321


includes a schematically illustrated apparatus


325


which is operative (if formation of the coil spring was not completed by the wire forming mechanism(s)


303


) to complete the forming of the coil springs by finally bending the ends of the axially spaced terminal coils and which is operative to temper the coil springs during travel therealong to the transfer conveyor


121


at the coil spring loading station


153


. Any suitable final bending and coil spring tempering apparatus can be employed, such as the apparatus disclosed in New Zealand Patent Application Serial No. 08/964,259, filed May 27, 1996, and entitled “Spring Formation”.




The delivery mechanism or conveyor


321


is arranged to deliver the fully formed and tempered coil springs to the pallets


161


of the transfer conveyor


121


when, as already noted, the pallets


161


are located in a vertical disposition or orientation. The delivery mechanism or conveyor


321


can also include a mechanism (not shown) for angularly orientating the coil spring ends so that, upon delivery of the coil springs to the transfer conveyor


121


, the coil spring ends will be properly orientated on the transfer conveyor


121


.




In the particularly disclosed construction, as shown in

FIGS. 20 through 24

, the delivery mechanism or conveyor


321


of the coil spring forming machine(s)


113


,


115


is mounted on the coil spring forming machine frame


221


and includes a pathway


330


including a funnel portion


332


(see

FIG. 22

) and a delivery portion


334


. While other constructions can be employed, the funnel portion


332


is located in the transfer station


315


and includes two opposed plates


338


which converge in the upward direction and which at their upper ends, is respectively include top segments


340


extending vertically in horizontally spaced relation. As the spoke assembly


291


rotatably advances and swings the associated coil spring upwardly, the opposed plates


338


serve to slightly axially compress the coil spring.




The delivery portion


334


extends generally horizontally between a receiving end extending from the funnel portion


332


to a delivery end located adjacent the coil spring loading station


153


and includes a floor or bottom plate


350


and a pair of horizontally spaced side plates or walls


352


which extend upwardly from the floor or bottom plate


350


, and which, in general, extend in generally coplanar relation from the inside surfaces of the top segments


340


of the opposed plates


338


of the funnel portion


332


and terminate in spaced relation to the coil spring loading station


153


.




The delivery portion


334


also includes a plurality of paddles or pushers


360


which are fixed to a flexible drive chain


362


for common travel therewith and which travel in an orbit including an upper run located adjacent the floor or bottom plate


350


of the pathway


330


. As already indicated, the drive chain


362


is driven or powered by the main forming machine driving device


225


. As the drive chain


362


moves along the upper run, the paddles or pushers


360


extend upwardly from the floor or bottom plate


350


of the delivery portion


334


of the pathway


330


and between the side plates


352


to engage the coil springs and displace the coil springs from the receiving end to the delivery end of the delivery portion


334


.




At the coil spring receiving end thereof, the delivery portion


334


also includes stationary and moveable structure for turning the coil spring through about 90 degrees and for advancing the coil springs into positions for engagement by the paddles or pushers


360


for advancement to the coil spring delivery end.




While other constructions can be employed, in the disclosed construction, the stationary structure includes, adjacent each of the side plates or walls


352


, a downwardly opening recess


370


and a forwardly located wall segment


372


. As a coil spring is swung upwardly by the spoke assembly


291


and after slight compression by the convergent opposed plates


338


, the upwardly leading flat segments of the terminal or end coils of the coil spring enter into the recesses


370


. While other constructions can be employed, in the disclosed construction, the moveable structure includes a reciprocable transfer bracket


390


which is advanced and retracted relative to the receiving end of the pathway


330


between retracted and extended positions and which includes two horizontally spaced and extending legs


392


moveable along the side plates or walls


352


adjacent the bottom plate or wall


350


and respectively including stepped surfaces


394


which engage lower portions of the terminal or end coils of the coil spring to rotate the coil spring about a fulcrum defined by engagement of the coil spring with the wall segments


372


in response to advancement of the legs


392


in the horizontal direction toward the delivery end of the delivery portion


334


. After such rotation and advancement toward the delivery end, the coil spring is located in position to be engaged by one of the paddles or pushers


360


as the paddles or pushers


360


advance along the upper run of the orbital path and enter behind the coil spring.




Any suitable arrangement can be employed to advance and retract the moveable structure or transfer bracket


390


between the retracted and extended positions. In the disclosed construction, pneumatic cylinders or rams


396


, connected between the frame


221


and the transfer bracket


390


, are employed.




At the coil spring delivery end, the delivery portion


334


also includes moveable structure for advancing coil springs from the pushing paddles


360


and into the coil spring loading station


153


where the coil springs is engaged by, magnetically attracted to, and held by the transfer conveyor


121


. While other constructions can be employed, in the disclosed construction, the moveable structure is in the form of a delivery bracket


400


which is advanced and retracted relative to the delivery end of the delivery portion


334


between retracted and advanced positions and which includes two horizontally spaced and extending legs


402


moveable along respective horizontal paths respectively located immediately laterally outside of the side plates or walls


352


and immediately beyond the end of the side plates or walls


352


adjacent the loading station


153


and hence the transfer conveyor


121


. The legs


402


each include a recessed cutout or notch


404


which, when the legs


402


are in the retracted position, and in response to coil spring advancement by one of the paddles or pushers


360


beyond the delivery ends of the side plates or walls


352


, receives the terminal or end coils of the coil spring in response to axially expansion of the coil spring to a less compressed condition. Stationary plates


408


located laterally outwardly of the legs


402


and fixed to the frame


221


prevent excessive expansion of the coil spring. Upon receipt of the terminal or end coils of the coil spring in the recessed cutouts or notches


404


, the delivery bracket


390


is advanced from the retracted position to the advanced position wherein the coil spring is located in the loading station


153


between one of the movable pallets


161


and a stationary arcuate guide


410


.




Any suitable arrangement can be employed to advance and retract the delivery bracket


400


between the retracted and advanced positions. In the disclosed construction, pneumatic cylinders or rams


406


, connected between the frame


221


and the delivery bracket


400


, are employed.




In the embodiment shown in

FIG. 2

, as will be is more fully disclosed hereinafter, the coil spring forming machines


113


and


115


simultaneously deliver coil springs to the transfer conveyor


121


so that the coil springs are located in side-by-side relation in the direction of travel of the transfer conveyor


121


. In this regard, the delivery mechanism or conveyor


321


of one of the coil spring forming machines


113


and


115


is located vertically (as shown in

FIG. 2

) so as to deliver coil springs to the upper half of the pallet


161


which extends vertically in the loading station


153


. The other of the coil spring forming machines


113


and


115


is located or arranged so that the delivery mechanism or


321


is at a lower vertical location so as to deliver coil springs to the lower half of the same pallet in the loading station


153


.




In the embodiment shown in

FIG. 7

, as will be more fully disclosed hereinafter, the coil spring forming machines


113


and


115


alternately deliver coil springs to the transfer conveyor


121


. More specifically, one of the coil spring forming machines


113


and


115


is operative to deliver a coil spring to the pallet


161


which extends vertically in the loading station


153


and then, after an incremental advancement of the transfer conveyor


121


, the other one of the coil spring forming machines


113


and


115


is operative to deliver a coil spring to the next pallet


161


which is then vertically located in the loading station


153


.




Alternatively, if desired, the coil spring forming machine(s)


113


and


115


can be arranged to temper the coil springs by a suitable tempering mechanism


351


located at a tempering station situated along the path of the spoke assembly


291


and during the dwell of the spoke assembly


291


between energizations of the main forming machine drive servo-motor


255


. Also, if desired, the coil spring forming machine(s)


113


and


115


can be located so as to enable the spoke assembly


291


to directly and serially deliver fully formed and tempered coil springs to the transfer conveyor


121


, without employing the delivery mechanism or conveyor


321


described above.




In another alternative construction, a linearly operating transport device or mechanism (not shown) can be employed (in place of the spoke assembly


291


) between a coil spring forming head and the loading station


153


associated with the transfer conveyor


121


. More specifically, in this construction, the transport mechanism (not shown) serves to linearly carry a partially formed coil spring from a suitable coil spring forming head to a first or coil spring bending or knotting station (which includes a suitable mechanism for bending or knotting), and, simultaneously, to carry the previously formed coil spring from the first station to a second or tempering station (including a suitable tempering device). Thereafter, the tempered coil spring can be delivered to the loading station


153


by another coil spring conveying device. In general, any suitable construction can be employed for transporting coil springs from the coil spring forming heads to the loading station


153


of the transfer conveyor


121


.




The coil spring forming and assembling machine


111


also includes the before-mentioned control means or system


135


which coordinates the operation of the coil spring forming machine(s)


113


and


115


and the transfer conveyor


121


(as well as the transfer apparatus


125


and the assembly apparatus


131


). In response to operation of the control system


135


, one operational cycle of the conveyor drive servo-motor


155


causes one incremental advance of the transfer conveyor


121


. Upon completion of such incremental conveyor assembly advance, the first and second main forming machine drive servo-motors


225


and


226


are energized to cause advancement by the wire feed servo-motor


232


of the wire


250


through the coil forming head


201


, thereby partially forming a coil spring by the associated coil forming head


201


, to cause one increment of rotation of the associated spoke assembly


291


by the associated main forming machine drive servo-motor


225


or


226


, to cause one operation of the bending mechanism


303


, to cause one operation of the tempering mechanism


351


(if included), and to cause delivery of one fully completed and tempered coil spring by the delivery mechanism


321


to the transfer conveyor


121


. In normal operation, the main forming machine drive servo-motor


225


is actuated several times, in respective response to an equal number of incremental advancements of the transfer conveyor


121


, before full completion and tempering of a coil spring and delivery thereof takes place. However, during normal operation, one coil spring is completed for each incremental advancement of the transfer conveyor


121


.




In the embodiment shown in

FIG. 2

, the control system


135


is operative to automatically and non-selectively cause energization of the conveyor drive servo-motor


155


through one operational cycle in response to completion of one operational cycle of both of the first and second main forming machine drive servo-motors


225


and


226


and is also operative to automatically and non-selectively cause simultaneous energization of the first and second forming machine drive servo-motors


225


and


226


in response to completion of one operational cycle of the conveyor drive servo-motor


155


.




In this last regard, the transfer conveyor drive servo-motor


155


is serially and incrementally operated in response to serial completion of coil springs by the coil spring forming machines


113


and


115


. In turn, the main forming machine drive servo-motors


225


and


226


of the coil spring forming machines


113


and


115


are actuated or energized to complete full formation, tempering, and delivery to the vertically extending pallets


161


in response to completion of each incremental advance of the transfer conveyor


121


. Thus, every time the transfer conveyor


121


completes one incremental advancement, thereby locating one of the platens


161


in a vertical disposition in the loading station


153


, the coil spring forming machines


113


and


115


are each energized so as to complete one coil spring and to deliver the completed coil spring to the vertically extending pallet


161


which is then at rest in the loading station


153


.




Still more specifically,

FIG. 16

illustrates diagrammatically one embodiment of the control system


315


. As depicted therein, the conveyor servo-motor


155


and the first and second main forming machine drive servo-motors


225


and


226


are normally off.




The conveyor drive servo-motor


155


can be initially energized by the operator, and thereafter, in response to completion of one operational cycle of the conveyor drive servo-motor


155


, the conveyor drive servo-motor


155


is deenergized or turned off and remains turned off until completion of the next cycle of both of the first and second main forming machine servo-motors


225


and


226


. In addition, completion of one operational cycle of the conveyor drive servo-motor


155


produces an energizing signal which is sent to both the first and second main forming machine servo-motors


225


and


226


, whereby both servo-motors are energized or turned on. Thereafter, upon completion of one operational cycle of both of the first and second main forming machine servo-motors


225


and


226


, the first and second forming machine drive servo-motors


225


and


226


are deenergized or turned off and remain turned off until completion of the next cycle of the conveyor drive servo-motor


155


. In addition, completion of one operational cycle of both of the first and second main forming machine servo-motors


225


and


226


, turns on or restarts the conveyor drive servo-motor


155


.




Energization of the main forming machine drive servo-motors


225


and


226


serves also to derivatively energize the wire feed servo-motors


232


for an appropriate period of time to complete one cycle of the wire feed servo-motors


232


. In turn, energization of the wire feed servo-motors


232


serves to energize, i.e., to turn on and off, the pitch control and diameter control servo-motors


239


and


249


for an appropriate period of time to complete one cycle of these servo-motors, all within the time period of one operational cycle of the main forming machine drive servo-motors


225


and


226


.




The control system


315


also includes a first counter


331


which is adjustable to vary the count and which counts the number of completed operational cycles of the conveyor drive servo-motor


155


, (or of one of the main forming machine drive servo-motors


225


and


226


). When a predetermined count is reached, i.e., when the desired number of number of coil springs are located on the transfer conveyor


121


in a row adjacent the coil spring transfer apparatus


125


, the counter


331


operates to prevent energization or turning on of the main forming machine servo-motors


225


and


226


. However, when the transfer of a row of coil springs from the transfer conveyor


121


is completed, the counter


331


is signaled, i.e., is reset, and operates to thereafter permit energization of the main forming machine drive servo-motors


225


and


226


. If the count is incomplete, the counter


331


permits the energization of, i.e., the initiation of the next cycle of, the wire feed servo-motors by the main forming machine servo-motors


225


and


226


so as to enable the wire feed servo-motors to feed another predetermined length of wire.




More specifically, in the control system shown in

FIG. 16

, each complete cycle of the conveyor servo-motor results in the sending of a signal to the counter


331


which, when the count is incomplete, permits initiation of the next cycle of the forming machine main servo-motors


225


and


226


. When the count is complete, the counter


331


prevents the next initiation of the cycle of the conveyor servo-motor


155


until reset in response to completion of the transfer of a row of coil springs from the transfer conveyor


121


to the coil spring transfer apparatus


125


.




Any suitable construction can be employed to provide the counter


331


.





FIG. 17

illustrates diagrammatically a second embodiment of the control system


315


. As depicted therein, the control system


315


is the same as that shown in

FIG. 16

, except that an additional counter


333


also serves to control energization of, or initiation of the next cycle of, the wire feed servo-motors


232


by the forming machine main servo-motors


225


and


226


, i.e., when the count at the counter


331


is incomplete, initiation of the next cycle of the wire feed servo-motors


232


by the forming machine main servo-motors


225


and


226


is allowed by the counter


331


. When the count is complete, but the counter


331


has not been reset, energization of the wire feed servo-motors


232


by the forming machine main servo-motors


225


and


226


is prevented. After resetting of the counter


333


, the counter


333


sends a signal permitting restarting of the conveyor servo-motor


155


.




Any suitable construction can be employed to provide the counter


333


.




As a consequence of the operation of the just-described embodiment of the control system


135


, each energization of the main forming machine drive servo-motors


225


and


226


of the coil spring forming machines


113


and


115


is dependent on, and occurs only in response to, each succeeding incremental advancement of the transfer conveyor


121


, and each energization of the conveyor drive servo-motor


155


(and consequent incremental advancement of the transfer conveyor


121


) is dependent on, and occurs only in response to, each preceding completion of one coil spring by each of the coil spring forming machines


113


and


115


.




The control system


135


also desirably includes one or more stop functions which is/are operable, in the event of a malfunction, such as the absence of a coil spring on one of the pallets


161


of the transfer conveyor


121


, to disable further operation of the conveyor drive servo-motor


155


and the main forming machine drive servo-motors


225


and


226


.




In operation of the machine assembly


111


as thus far disclosed, the conveyor drive servo-motor


155


is periodically and incrementally operated to move the transfer conveyor


121


through such distance as will locate the pallet


161


in a vertical orientation. Thereafter, and as a consequence of completion of the incremental movement of the transfer conveyor


121


, the coil spring forming machines


113


and


115


are operated to respectively produce and deliver a coil spring to the vertically extending pallet


161


. Thereafter, the conveyor drive servo-motor


155


is again energized to again advance the transfer conveyor


121


though the given incremental distance which is approximately equal to the length of the pallets


161


in the direction of conveyor advance.




In operation of the embodiment shown in

FIG. 2

, the machine assembly


111


is energized to cause each of the coil spring forming machines


113


and


115


to simultaneously deliver a coil spring to the one of the pallets


161


which is vertically extending during non-movement of the transfer conveyor


121


. As a consequence, each pallet


161


receives two coil springs in side-by-side relation, and in slightly spaced relation in the direction of conveyor travel, with one of the coil springs desirably being of left-handed construction, and with the other of the coil springs desirably being of right-handed construction. If desired, both coil springs could be of the same hand.




In another embodiment which includes only a single coil spring forming machine which directly supplies fully formed coil springs to the transfer conveyor


121


, i.e., the spring assembly machine


111


shown in

FIG. 1

with only one coil spring forming machine, the control system


315


is operative to automatically and non-selectively cause energization of the conveyor drive servo-motor


155


in response to completion of one operational cycle of the main forming machine drive servo-motor


255


, and, thereafter, is operative to automatically and non-selectively cause energization of the main forming machine drive servo-motor


225


in response to completion of one operational cycle of the conveyor drive servo-motor


155


. Thereafter, completion of one operational cycle of the main forming machine drive servo-motor


225


causes energization of the conveyor drive servo-motor


155


to provide one incremental advance of the transfer conveyor


121


, and so on.




More particularly in the this regard, shown schematically in

FIG. 18

is a control system


411


for the machine assembly shown in FIG.


6


. The control system


411


is generally identical to the control system


315


shown in

FIG. 16

, except that the counter


331


is omitted, and except that the signal generated in response to completion of one cycle of the conveyor servo-motor


155


causes a switching device


421


to alternately energize the first and second main forming machine drive servo-motors


225


and


226


. In addition, as distinguished from the control systems


315


shown in

FIGS. 16 and 17

, the conveyor servo-motor


155


can be energized by a signal from either of the forming machine main servo-motors


225


and


226


. Thus, after completion of a first cycle of the conveyor drive servo-motor


155


, one of the first servo-motors


225


and


226


is energized or turned on, while the other one of the forming machine drive servo-motors


225


and


226


remains deenergized, and then, after completion of the next cycle of the conveyer drive servo-motor


155


, the other one of the servo-motors


225


and


226


is energized or turned on, while the first mentioned one of the servo-motors


225


and


226


remains deenergized.




Any suitable construction can be employed to provide the switching device


421


.




In addition, the control system


411


of

FIG. 18

differs from the control system


315


of

FIG. 16

in that the power line to the conveyor drive servo-motor


155


includes first and second parallel branches


427


and


429


which are respectively connected to the lines which carry the signals indicating completion of the operational cycles of the first and second main forming machine drive servo-motors


225


and


226


. Thus, whenever the operational cycle of one of the main forming machine drive servo-motors


225


and


226


is completed, the conveyor drive servo-motor


155


is again energized or turned on.




In the embodiment shown in

FIG. 6

, the control system


135


(a) is operative to automatically and non-selectively cause energization of the conveyor drive servo-motor through a first operational cycle in response to completion of one operational cycle of the second main forming machine drive servo-motor


226


, (b) is operative to automatically and non-selectively cause energization of the first main forming machine drive servo-motor


225


in response to completion of the first operational cycle of the conveyor drive servo-motor


155


, (c) is operative to automatically and non-selectively cause energization of the conveyor drive servo-motor


155


through a second operational cycle in response to completion of one operational cycle of the first main forming machine drive servo-motor


225


, (d) is operative to automatically and non-selectively cause energization of the second main forming machine drive servo-motor


226


in response to completion of the second operational cycle of the conveyor drive servo-motor


155


.




Thus, in operation of the embodiment shown in

FIG. 6

, the main forming machine drive servo-motors


225


and


226


are alternately energized to cause the coil spring forming machines


113


and


115


to alternately deliver completed coil springs to the transfer conveyor


121


. More specifically, the machine assembly is arranged so that, initially, one of the coil forming machines


113


and


115


delivers one end convolution of a coil spring into the pocket


170


of one pallet


161


when the one pallet is located in vertically extending orientation in the loading station


153


during non-movement of the transfer conveyor


121


. Thereafter, the transfer conveyor


121


is advanced through one increment of movement approximately equal to the length of one pallet


161


and so as to locate the next one of the pallets


161


in vertically extending orientation in the loading station


153


. Thereafter, the other of the coil spring forming machines


113


and


115


delivers one end convolution of another coil spring (which is desirably of the other hand) into the pocket


170


of the next pallet


161


when the next pallet


161


is located in vertically extending orientation in the loading station


153


during non-movement of the transfer conveyor


121


.




As a consequence, every other pallet


161


receives one coil spring which is desirably of a given hand, i.e., either left- or right-hand, while all of the intermediate pallets


161


receive one coil spring which, desirably, is of the other hand. However if desired, the coil forming machines


113


and


115


could be operated to deliver coils of the same hand to the transfer conveyor.




In another embodiment of the invention which is shown in FIG.


15


and which is otherwise similar to the arrangement shown in

FIG. 6

, the control system


315


is arranged to afford selective delivery by the coil spring forming machines


113


and


115


to the transfer conveyor


121


. This capability permits the formation of coil spring rows (on the transfer conveyor


121


) of a selected number of coil springs formed by one of the coil spring forming machines


113


and


115


, followed by another selected number of coil springs formed by the other one of the coil spring forming machines


113


and


115


. As a consequence, when one of the coil spring forming machines


113


and


115


manufactures coil springs of one selected configuration and the other of the coil spring forming machines


113


and


115


manufactures coil springs of another configuration, spring assemblies can be manufactured with predetermined variations in springiness.




More particularly, the control system


315


can be arranged to include first and second counting and switching devices


413


and


415


which are of any suitable construction, which are respectively connected to the main forming machine drive servo-motors


225


and


226


of the first and second coil spring forming machines


113


and


115


, which are connectable to and disconnectable from the conveyor drive servo-motor


155


and which respectively include count adjusting knobs


423


and


425


, whereby the number of coil springs to be delivered from either one of the first and second coil spring forming machines


113


and


115


to the transfer conveyor


121


, before delivery of coil springs from the other one of the machines to the transfer conveyor


121


, can be varied from 0 to X. In the alternative, if desired, the first and second counting and switching devices


413


and


415


can be connected to the conveyor drive servo-motor


155


and can be respectively connectable to and disconnectable from the main forming machine drive servo-motors


225


and


226


of the first and second coil spring forming machines


113


and


115


.




In operation of one embodiment, initially, the first and second counting and switching devices


413


and


415


are arranged so that the first counting and switching device


413


is connected to the conveyor drive servo-motor


155


, and so that the second counting and switching device


415


is disconnected from the conveyor drive servo-motor


155


. When thus arranged, and after manipulation of the adjusting knob


423


of the first counting and switching device


413


to select a desired number of successive operational cycles of the first coil spring forming machine


113


, the arrangement is (a) thereafter operative to effect the selected desired number of successive operational cycles of the first coil spring forming machine


113


by successive energization of the main forming machine drive servo-motor


225


of the first coil spring forming machine


113


in response to each successive completion of the selected desired number of operational cycles of the conveyor drive servo-motor


155


, and (b) thereafter, and upon completion of the selected desired number of operational cycles of the conveyor drive servo-motor


155


, is operable to effect disconnection of the first counting and switching device


413


from the conveyor drive servo-motor


155


and connection of the second counting and switching device


415


to the conveyor drive servo-motor


155


.




After such connection and disconnection, the second counting and switching device


415


, and assuming that the adjusting knob


425


of the second counting and switching device


415


has been adjusted to select a desired number of successive operational cycles of the second coil spring forming machine


115


, the arrangement is (a) thereafter operative to effect the selected desired number of successive operational cycles of the second coil spring forming machine


115


by successive energization of the main forming machine drive servo-motor


226


of the second coil spring forming machine


115


in response to each successive completion of the selected desired number of operational cycles of the conveyor drive servo-motor


155


, and (b) thereafter, and upon completion of the selected desired number of operational cycles of the conveyor drive servo-motor


155


, is operative to effect disconnection of the second counting and switching device


415


from the conveyor drive servo-motor


155


and re-connection of the first counting and switching device


413


to the conveyor drive servo-motor


155


. Thereafter the first counting and switching device


413


operates as described just above.




Because it is believed that anyone skilled in the art can readily construct the control system


135


to obtain the operations disclosed above in detail, description of particular devices and components included in the control system


135


is believed to be unnecessary.




Various of the features of the invention are set forth in the following claims.



Claims
  • 1. A delivery mechanism for delivering a coil formed by a coil forming machine to a transfer conveyor, wherein the coil includes a non-circular outer peripheral portion, the delivery mechanism comprising:a delivery portion having a coil receiving end, a delivery end, and spaced apart side walls extending between the receiving end and the delivery end and defining therebetween a coil delivery pathway portion, the coil receiving end including at least one stationary member adjacent at least one of the side walls, wherein the stationary member is configured to engage the non-circular outer peripheral portion of the coil to impart rotation to the coil during travel in the coil delivery pathway portion.
  • 2. The delivery mechanism of claim 1, wherein the stationary member includes a seat portion configured to engage the non-circular outer peripheral portion of the coil.
  • 3. The delivery mechanism of claim 1, wherein a portion of the stationary member defines a pivot point about which the coil pivots during travel in the coil delivery pathway portion.
  • 4. The delivery mechanism of claim 3, wherein the coil is pivoted at least approximately 90 degrees.
  • 5. The delivery mechanism of claim 1, wherein the coil is moveable in the coil delivery pathway portion by means of a moveable member moveable between a retracted position and an advanced position, and wherein the moveable member is engageable with the coil to pivot the coil during movement of the moveable member from the retracted position toward the advanced position.
  • 6. The delivery mechanism of claim 5, wherein the stationary member is located between the retracted position and the advanced position of the moveable member such that the coil is pivoted about the stationary member during movement of the moveable member from the retracted position to the advanced position.
  • 7. The delivery mechanism of claim 1, further including a pusher that moves the coil from the coil receiving end to the coil delivery end.
  • 8. The delivery mechanism of claim 1, further including a moveable member which is moveable between a retracted position, wherein the coil engages the moveable member, and an advanced position, wherein the moveable member places the coil in engagement with the transfer conveyor.
  • 9. A delivery mechanism for delivering a coil formed by a coil spring forming machine to a transfer conveyor, the delivery mechanism comprising:a delivery portion having a coil receiving end and a delivery end located adjacent the transfer conveyor, a coil supply mechanism for supplying coils one at a time to the coil receiving end, and a moveable member moveable between a retracted position and an advanced position, wherein movement of the moveable member from its retracted position to its advanced position is operable to move the coil from the coil receiving end to the delivery end and to place the coil in engagement with the transfer conveyor.
  • 10. A method of transferring a coil along a coil conveying pathway and in a coil conveying direction from a coil spring forming machine to a transfer conveyor, the method comprising:placing the coil into a seat associated with the pathway; stationarily maintaining the coil in engagement with the seat; rotating the coil while moving the coil out of engagement with the seat, wherein the seat is configured to engage at least a portion of the coil such that movement of the coil away from the seat is operable to rotate the coil; advancing the coil along the pathway; and transferring the coil from the pathway to the transfer conveyor.
  • 11. The method of claim 10, wherein the pathway includes a delivery portion having a receiving end and a moveable member in the receiving end, the moveable member being moveable between a retracted position and an advanced position, and wherein rotating the coil further includes moving the moveable member from the retracted position toward the advanced position to pivot the coil about the seat.
  • 12. The method of claim 10, wherein rotating the coil includes pivoting the coil at least approximately 90 degrees about the seat.
  • 13. The method of claim 10, wherein advancing the coil includes engaging the coil with a pusher and moving the pusher toward the transfer conveyor.
  • 14. The method of claim 10, wherein the pathway includes a delivery portion having a delivery end and a moveable member in the delivery end, the moveable member being moveable between a retracted position and an advanced position, and wherein transferring the coil from the pathway to the transfer conveyor includes engaging the coil with the moveable member while the moveable member is in the retracted position and moving the moveable member toward the advanced position.
  • 15. A delivery mechanism for delivering a coil formed by a coil forming machine to a transfer mechanism, comprising:a coil conveying pathway including a coil receiving area and a discharge area, wherein the discharge area is located adjacent the transfer mechanism; wherein each coil includes at least one non-circular external portion, and wherein the coil receiving area includes a seat configured to receive and engage the non-circular external portion of the coil; and a moveable member for moving each coil away from the coil receiving area in the coil conveying pathway, wherein engagement of the coil with the seat is operable to rotate the coil during movement of the coil away from the coil receiving area by operation of the moveable member.
  • 16. The delivery mechanism of claim 15, wherein the moveable member is moveable between a retracted position and an advanced position, and wherein the moveable member is engageable with the coil at the coil receiving area to rotate the coil during movement of the moveable member from the retracted position toward the advanced position.
  • 17. The delivery mechanism of claim 15, wherein the moveable member is moveable between a retracted position, wherein the moveable member engages the coil in the coil receiving area, and an advanced position, wherein the moveable member pushes the coil within the coil conveying pathway toward the transfer mechanism.
  • 18. A method of transferring a coil from a coil forming machine to a transfer mechanism, comprising the steps of:moving the coil in a first direction from the coil forming machine into engagement with a stationary member associated with a coil receiving area; moving the coil in a second direction transverse to the first direction away from the coil receiving area and out of engagement with the stationary member to a coil transfer area, wherein the stationary member is operable to engage the coil such that movement of the coil out of engagement with the stationary member is operable to rotate the coil to a predetermined coil orientation; and supplying the coil to the transfer mechanism from the coil transfer area.
  • 19. A coil transfer arrangement for transferring coils from a coil forming machine to a downstream station, comprising:an arm mechanism that engages each coil and moves the coil in a first direction away from a coil forming machine to a receiving area; a moveable member located at the receiving area, wherein the moveable member is moveable from a retracted position to an advanced position, and wherein the moveable member is configured and arranged to engage each coil at the receiving area and to move the coil in a second direction, transverse to the first direction, away from the receiving area to a transfer area; and a transfer mechanism located at the transfer area for receiving coils moved to the transfer area by the moveable member and for moving the coils toward the downstream station.
RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No. 09/365,371 filed Jul. 30, 1999, now abandoned, which is a continuation-in-part of U.S. application Ser. No. 09/005,346 filed Jan. 9, 1998, now U.S. Pat. No. 5,950,473 issued Sep. 14, 1999, which is a continuation-in-part of U.S. Provisional Application Serial No. 60/057,213, filed Aug. 29, 1997. This application also claims priority of U.S. Provisional Application Serial No. 60/120,832, filed Feb. 19, 1999.

US Referenced Citations (11)
Number Name Date Kind
2059117 King et al. Oct 1936 A
3205915 Kamp Sep 1965 A
3906766 Sato Sep 1975 A
4014371 Walker et al. Mar 1977 A
4111241 Crown Sep 1978 A
4112721 Takase et al. Sep 1978 A
4413659 Zangerle Nov 1983 A
4492298 Zapletal et al. Jan 1985 A
5243746 Shinichi Sep 1993 A
5477893 Wentzek et al. Dec 1995 A
5579810 Ramsey et al. Dec 1996 A
Foreign Referenced Citations (6)
Number Date Country
29 46 656 Oct 1985 DE
43 23 009 Jul 1992 DE
0 044 464 Jan 1982 EP
0 369 173 May 1990 EP
2 238 546 Feb 1975 FR
WO0047348 Aug 2000 WO
Non-Patent Literature Citations (3)
Entry
Draht, Jan. 1984, by Dr. H. Birkmann, pp. 18-21.
Draht, Sep. 1993, by Thomas Blum, Dietmar Sautter, Theo Tröster, pp. 504-514.
Brochure “Announcing the World's Fastest, Most Advanced Pocket Spring Technology”, circulated by Elfex International Limited of Pickering, Ontario L1WZ9 Canada.
Provisional Applications (2)
Number Date Country
60/057213 Aug 1997 US
60/120832 Feb 1999 US
Continuations (1)
Number Date Country
Parent 09/365371 Jul 1999 US
Child 09/753936 US
Continuation in Parts (1)
Number Date Country
Parent 09/005346 Jan 1998 US
Child 09/365371 US