Canted coil spring rings each with a first plurality of coils having first coil major and minor axes; a second plurality of coils each having second coil major and minor axes; the coils of the first plurality of coils alternating with the coils of the second plurality of coils according to an alternating pattern. The spring rings having inner and outer perimeters and wherein the inner perimeter of the spring ring is defined by at least said first plurality of coils. The resulting configuration of the spring ring has improved spacing along the inner perimeter, among others, with respect to a similar canted coil spring ring having a constant coil cross section, such as a coil length with all similar coils.

Canted coil spring rings each with a first plurality of coils having first coil major and minor axes; a second plurality of coils each having second coil major and minor axes; the coils of the first plurality of coils alternating with the coils of the second plurality of coils according to an alternating pattern. The spring rings having inner and outer perimeters and wherein the inner perimeter of the spring ring is defined by at least said first plurality of coils. The resulting configuration of the spring ring has improved spacing along the inner perimeter, among others, with respect to a similar canted coil spring ring having a constant coil cross section, such as a coil length with all similar coils.

A collision-proof spring transfer takes place in the process, which comprises a continuous transfer of coil springs from the pipeline through an exit opening of the pipeline into assigned spring receptacles, and an automatic prevention of any re-entry of coil springs that have passed through the exit opening in the direction of the spring receptacle and rebound from the region of the spring receptacle back into the pipeline.

A method of producing helical springs by spring winding with a numerically controlled spring winding machine includes feeding a wire, controlled by an NC control program, through a feed device to a forming device of the spring winding machine, forming a helical spring from the wire with tools of the forming device, defining a desired nominal geometry of the helical spring and an NC control program adapted to produce the nominal geometry, measuring an actual position of a selected structural element of the helical spring relative to a reference element at least one measurement time, which occurs after a start and before an end of production of the helical spring in a measurement area which is at a finite distance from the forming device in a longitudinal direction of the helical spring, wherein the distance is less than an overall length of the finished helical spring, comparing the actual position with a nominal position of the structural element for the measurement time to determine a current position difference, which represents a difference between an actual position and the nominal position at the measurement time, and controlling the position by at least one of the tools of the forming device, which tool determines a pitch of the helical spring as a function of the position difference.

A method of producing helical springs by spring winding with a numerically controlled spring winding machine includes feeding a wire, controlled by an NC control program, through a feed device to a forming device of the spring winding machine, forming a helical spring from the wire with tools of the forming device, defining a desired nominal geometry of the helical spring and an NC control program adapted to produce the nominal geometry, measuring an actual position of a selected structural element of the helical spring relative to a reference element at least one measurement time, which occurs after a start and before an end of production of the helical spring in a measurement area which is at a finite distance from the forming device in a longitudinal direction of the helical spring, wherein the distance is less than an overall length of the finished helical spring, comparing the actual position with a nominal position of the structural element for the measurement time to determine a current position difference, which represents a difference between an actual position and the nominal position at the measurement time, and controlling the position by at least one of the tools of the forming device, which tool determines a pitch of the helical spring as a function of the position difference.

In accordance with an exemplary embodiment, a method for manufacturing a bypass valve of a turbine engine control system is described. The bypass valve includes a proportional valve and an integrator valve and the integrator valve includes an integrator spring assembly. The method includes forming the integrator spring assembly using an additive manufacturing technique. The integrator spring assembly comprises first and second end portions with a spring portion disposed between the first and second end portions. The first and second end portions and the spring portion are formed as an integral unit without welding or brazing using the additive manufacturing technique. The method further includes assembling the integrator spring assembly, the integrator valve, and the proportional valve into a complete bypass valve assembly.

A wire supply station comprises a container 34 in which the wire is retained in a multitude of loops (not shown) of substantially the same diameter around a cylindrical inside surface of the drum. The wire 16 emerges from the drum 34 under no tension and substantially straight. It is then fed between guide or feed rollers 20 into the coiling head 12.

The wire 16 is formed into a continuous coil, from which lengths are cut by a cutter (not shown) to form individual coil springs 24. The individual coil springs 24 are then carried by the spring transfer station 26 to the fabric pocket welding station 28 where they become encased in individual pockets when the welding heads 30 weld the material.

Pre-straightening the wire before storing it in loops inside the cylindrical drum 34 allows for a more consistent pocket spring, and ultimately a flatter spring unit/mattress as any pre-stressing of the wire, caused by the drawing process used to manufacture it, is neutralised leaving the wire largely stress-free. This means that there is no need to compensate for, or break, the forces inherent in the wire before feeding it to the coiler. Accordingly the accumulator is not necessary and the wire supply can be positioned together with the coiling device, preferably above or below the coiling device, to take up less footprint in the factory.

A wire supply station comprises a container 34 in which the wire is retained in a multitude of loops (not shown) of substantially the same diameter around a cylindrical inside surface of the drum. The wire 16 emerges from the drum 34 under no tension and substantially straight. It is then fed between guide or feed rollers 20 into the coiling head 12.

The wire 16 is formed into a continuous coil, from which lengths are cut by a cutter (not shown) to form individual coil springs 24. The individual coil springs 24 are then carried by the spring transfer station 26 to the fabric pocket welding station 28 where they become encased in individual pockets when the welding heads 30 weld the material.

Pre-straightening the wire before storing it in loops inside the cylindrical drum 34 allows for a more consistent pocket spring, and ultimately a flatter spring unit/mattress as any pre-stressing of the wire, caused by the drawing process used to manufacture it, is neutralised leaving the wire largely stress-free. This means that there is no need to compensate for, or break, the forces inherent in the wire before feeding it to the coiler. Accordingly the accumulator is not necessary and the wire supply can be positioned together with the coiling device, preferably above or below the coiling device, to take up less footprint in the factory.

A method of manufacturing a coil spring formed by processing a base material made of a wire material includes: performing cold forming on the base material to fabricate a shaped material of spiral shape; performing quenching on the shaped material; and performing tempering on the shaped material obtained after quenching, by using electrical heating.