A coil spring manufacturing device includes a mandrel around which a wire is wound, a feed mechanism which feeds the wire toward the mandrel, guide members which guide the wire, a chuck which fixes a distal end of the wire, and a clamp mechanism. The clamp mechanism sandwiches the wire from both sides before the distal end of the wire reaches the mandrel. Further, the clamp mechanism can be rotated about a fulcrum by rotation actuator, and can also be slid in a direction along an axis of the mandrel by sliding actuator. In a state in which the wire is sandwiched by the clamp mechanism, the clamp mechanism is rotated, and if necessary, is slid. Thereby, a bent portion for a negative pitch portion of a coil spring is formed at a part of the wire.

A coil spring manufacturing device includes a mandrel around which a wire is wound, a feed mechanism which feeds the wire toward the mandrel, guide members which guide the wire, a chuck which fixes a distal end of the wire, and a clamp mechanism. The clamp mechanism sandwiches the wire from both sides before the distal end of the wire reaches the mandrel. Further, the clamp mechanism can be rotated about a fulcrum by rotation actuator, and can also be slid in a direction along an axis of the mandrel by sliding actuator. In a state in which the wire is sandwiched by the clamp mechanism, the clamp mechanism is rotated, and if necessary, is slid. Thereby, a bent portion for a negative pitch portion of a coil spring is formed at a part of the wire.

An arcuate spring having a plurality of coils which are configured and dimensioned to provide an arcuate shape to the spring and being substantially free of internal stresses which would tend to urge the coils into linear alignment. The spring is designed to function under load conditions while maintaining its natural arcuate shape. The spring is can be heated by use of an induction heating process.

A servo-rotating all-function tool module is provided for use with a spring forming machine and includes an axle rotating tool module that is mounted, together with an axle, to a front wall board and includes a tool and an axle slide base mounted to the axle, so that the axle slide base is acted upon by a force to slide along the axle, the tool is caused to press downward or return upward. A servo transmission module assembly is mounted to the spring forming machine to provide a driving force for causing the axle slide base to slide along the axle. Since the tool module is mounted, together with the axle, to a front wall board of the spring forming machine, the direction in which the tool approaches a wire can be varied by rotating the axle in order to conduct operations of bending at different angles and twisting/looping.

A servo-rotating all-function tool module is provided for use with a spring forming machine and includes an axle rotating tool module that is mounted, together with an axle, to a front wall board and includes a tool and an axle slide base mounted to the axle, so that the axle slide base is acted upon by a force to slide along the axle, the tool is caused to press downward or return upward. A servo transmission module assembly is mounted to the spring forming machine to provide a driving force for causing the axle slide base to slide along the axle. Since the tool module is mounted, together with the axle, to a front wall board of the spring forming machine, the direction in which the tool approaches a wire can be varied by rotating the axle in order to conduct operations of bending at different angles and twisting/looping.

A system for manufacturing a string of pocketed coil springs comprising: a coil-forming subsystem that produces two coil springs; a spring transporter subsystem that receives the two coil springs at a first position and conveys the two coil springs to a second position; a spring compressor subsystem that compresses the two coil springs; a fabric-folding subsystem that receives a piece of fabric and folds the fabric to create an open side; a spring inserter subsystem that receives the two compressed coil springs and inserts the two compressed coil springs between top and bottom surfaces of a folded piece of fabric; two welder subsystems that form first and second welds between top and bottom surfaces of the folded piece of fabric, the first welds and the second welds forming a plurality of pockets in the fabric, each of the plurality of pockets comprising a compressed coil spring.

The present invention is provided focusing on a servo press configured to enable high-speed/high-accuracy operation by numeric value control in the method for manufacturing an arc-shaped coil spring. The present invention provides a manufacturing method and a manufacturing device configured so that the curvature of the arc-shaped coil spring can be freely ensured. The manufacturing method includes the clamp step of fixing a straight cylindrical coil spring, the end portion detection step of detecting an end portion, a rotation angle position determination step, a pitch feeding step, a pressing member insertion step, and an insertion direction conversion step. The manufacturing method and the manufacturing device relate to the technology of continuously repeating the operation of pushing down a pressing member to an inter-pitch from above, thereby deforming the straight cylindrical coil spring into the coil spring with the curvature.

Apparatus for forming wire components, which are in this example springs, comprises a supply station (202), for supplying spring forming material, such as metallic wire W. The supply station includes a pair of guide rollers (204) and pair of driven feed rollers (206), mounted on a heavy support plate (216). The wire is fed through a flexible sheath FS to a remotely located wire shaping device, in particular a spring forming device 208, comprising forming tools (210), a pitch control tool (212) and a cutter (214). The forming tools (210) and the pitch control tool (212) form the wire into a spring S, which is cut from the supply of wire when it is complete. The tools (210, 212) and cutter (214) are controlled remotely from a control station (220) via a bundle of flexible control cables (222), which may include a power cable. The spring forming device 208 is mounted on a positioning member (224), such as a robot arm or moveable table, configured for three-dimensional movement, and/or optionally adjustments in inclination. Without the heavy plate (216) and rollers (205, 206), the spring forming device (208) is sufficiently light in weight and compact as to be moved by the positioning member (224) to a location in which springs are to be used, thereby avoiding the need for transportation apparatus to convey the springs from the place where they are formed to the place where they are to be used.

Apparatus for forming wire components, which are in this example springs, comprises a supply station (202), for supplying spring forming material, such as metallic wire W. The supply station includes a pair of guide rollers (204) and pair of driven feed rollers (206), mounted on a heavy support plate (216). The wire is fed through a flexible sheath FS to a remotely located wire shaping device, in particular a spring forming device 208, comprising forming tools (210), a pitch control tool (212) and a cutter (214). The forming tools (210) and the pitch control tool (212) form the wire into a spring S, which is cut from the supply of wire when it is complete. The tools (210, 212) and cutter (214) are controlled remotely from a control station (220) via a bundle of flexible control cables (222), which may include a power cable. The spring forming device 208 is mounted on a positioning member (224), such as a robot arm or moveable table, configured for three-dimensional movement, and/or optionally adjustments in inclination. Without the heavy plate (216) and rollers (205, 206), the spring forming device (208) is sufficiently light in weight and compact as to be moved by the positioning member (224) to a location in which springs are to be used, thereby avoiding the need for transportation apparatus to convey the springs from the place where they are formed to the place where they are to be used.

According to an embodiment, a coil spring is formed of a wire which is helically wound, and includes an end turn portion and an effective portion, and a surface of the wire in the end turn portion includes an area which is softer than a surface of the wire in the effective portion.