Wire shaping apparatus and method of shaping a wire

Abstract

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.

Claims

1. A wire shaping apparatus for shaping wire into springs, the apparatus comprising: a movable positioning member; a forming device mounted on the movable positioning member for moving the forming device, and a supply station, located remotely from the forming device and including a supply of spring wire for supplying a length of the spring wire to the forming device via a wire conduit, wherein the wire conduit comprises a sole mechanical connection between the supply station and the forming device, wherein the forming device includes: at least one tool for shaping a portion of the wire into a spring; and at least one tool for cutting the spring from the length of wire, wherein the moveable positioning member is configured to move the forming device as a whole relative to, and independently of, the supply station in at least two-dimensions during operation of the apparatus, such that the spring shaped and cut by the forming device is located in a desired position where the cut spring can be used by the independent moving of the forming device relative to the supply station in the at least two-dimensions.

2. The wire shaping apparatus according to claim 1, wherein the supply station includes feed apparatus comprising at least one pair of rollers.

3. The wire shaping apparatus according to claim 1, wherein the wire conduit is in the form of a sheath or sleeve for supplying the wire to the forming device.

4. The wire shaping apparatus according to claim 1, wherein the supply station is configured to supply pre-straightened, drum-coiled wire to the forming device.

5. The wire shaping apparatus according to claim 1, wherein the supply station comprises a container, in which the wire is retained in a multitude of loops of substantially the same diameter around a cylindrical inside surface of the container.

6. The wire shaping apparatus according to claim 1, wherein the forming device further comprises one or more additional tools including one or more of: a pitch controlling tool, a heating tool and a fixing tool.

7. The wire shaping apparatus according to claim 6, wherein the apparatus comprises one or more ancillary tools arranged in use to move with the forming device.

8. The wire shaping apparatus according to claim 7, wherein the one or more ancillary tools are arranged as part of the forming device.

9. The wire shaping apparatus according to claim 7, wherein the one or more ancillary tools include one or more of: a cutter, router, drill, cropper, trimmer, laser.

10. The wire shaping apparatus according to claim 6, wherein operation of the one or more tools of the forming device is controlled remotely by a control apparatus.

11. The wire shaping apparatus according to claim 10, wherein the control apparatus is configured to communicate with the one or more tools of the forming device through a cable.

12. The wire shaping apparatus according to claim 1, wherein the forming device is moveable in two, or three, dimensions.

13. The wire shaping apparatus according to claim 12, wherein movement of the forming device is caused by a moveable arm or platform.

14. A method of shaping a wire into springs, the method comprising: supplying a length of spring wire from a supply station that includes a supply of the spring wire to a remotely located forming device via a wire conduit, wherein: the wire conduit comprises a sole mechanical connection between the supply station and the forming device, the forming device includes at least one tool for shaping a portion of the spring wire into a spring and at least one tool for cutting the spring from the length of spring wire, and the forming device is mounted on a moveable positioning member, shaping a portion of the spring wire into a spring and cutting the spring from a remaining length of wire using the tools of the forming device while moving the moveable positioning member and the forming device mounted to the movable positioning member as a whole relative to, and independently of, the supply station in at least two-dimensions to place the spring in a desired position where the spring is to be used.

15. The method according to claim 14, including positioning the shaped portion of wire in relation to a work piece.

16. The method according to claim 14, the method comprising operating one or more tools of the forming device remotely by a control apparatus.

17. The wire shaping apparatus according to claim 1, wherein the moveable positioning member is configured to move the forming device as a whole relative to, and independently of, the supply station in three-dimensions.

Description

(1) A preferred embodiment of the present invention will now be described. By way of example only, with reference to the accompanying diagrammatic drawings, in which:

(2) FIG. 1 shows a previously considered spring forming apparatus; and

(3) FIG. 2 shows a wire shaping apparatus according to an embodiment of the present invention.

(4) Turning to FIG. 2, this shows schematically apparatus for forming wire components, which are in this example springs, generally at 200. A supply station 202, for supplying spring forming material, such as metallic wire W, 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.

(5) A wire payoff (not shown) such as a reel, spool or preferably a drum, supplies the rollers.

(6) 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 (not shown). 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.

(7) 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. This avoids 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. When springs of a different size or shape, or of a different wire gauge are to be used, they are formed and placed where they are needed, without the need to re-optimise a transportation apparatus.

(8) In another embodiment (not shown) the forming device and light weight rollers are mounted for common movement in relation to the wire payoff, such as a wire supply in the form of a drum of coiled wire.

(9) The control cables could comprise flexible rods or linkages, or the control could be provided wirelessly, or via electric cables. Similarly, the cutting tool 214 is shown as a mechanical device, but could, as an alternative (not shown) comprise an electric arc cutter, or similar.

(10) The springs could be heated locally at the spring forming device, so as to treat them, and also if desired to weld or otherwise attach them to an article, such as to a metal plate or clip, or other fixture.

(11) The forming device is also moveable with respect to a work piece, in one, two or preferably three dimensions, and optionally in inclination, with respect to a work piece.

(12) This versatility of the wire shaping apparatus according to embodiments of the present invention allows the forming and precise placement of wire components, such as springs of different types, where they are needed, either in or on another work piece/article or in an aperture or magazine, or onto a magnetic belt, without the need for separate transportation apparatus for different types of wire components.

(13) There are many examples of articles to which the apparatus and methods described above can precisely deliver shaped components. Such examples include, but are not limited to: automotive articles such as engines, suspensions and seating, other vehicles, plant and machinery and furniture.

(14) Whereas the above-described example is of forming springs, it will be understood that the apparatus and methods described herein could also be used to shape a portion of wire into a configuration other than a spring.

(15) Also, the term wire as used herein is intended to cover or include any filament, thread, tube or similar, whether solid or hollow, and whether metallic or not, which is capable of being shaped in the manner described above.

(16) Similarly, it will be understood by the skilled person that a single control apparatus may be used to control one, or more than one, of the tools of a plurality of forming devices. Thus, a relatively expensive control apparatus can be used with a plurality of less expensive wire shaping heads.

(17) The remote control of the one or more tools can be by mechanical, electrical or electronic means and may use cables and/or wires or wireless signal paths, or a combination of these.

(18) As stated above, the forming device and a relatively light weight feed apparatus may be arranged to move, for example together, independently of the supply station by mounting them on a moveable positioning member such as 224. Alternatively, the forming device may be arranged to move independently of the supply station and feed apparatus, one or both of which may be stationary.

(19) In another embodiment (not shown) the apparatus has one or more ancillary tools. The one or more ancillary tools may be arranged in use to move with the forming device, and are preferably arranged as part of the forming device. The one or more ancillary tools may include one or more of the following, but not limited to: a cutter, router, drill, cropper, trimmer, laser, and may be used, for example, to perform tasks, such as preparatory tasks or finishing tasks in respect of a work piece, in relation to which a shaped portion of wire is to be positioned. In one such example, a work piece may comprise a portion of foam into which formed springs are to be deposited. An ancillary tool, such as a router, may be used to create an aperture or recess for receiving a spring. Another ancillary tool, such as a cutter/trimmer/cropper tool, may be used to crop or trip the work piece.

(20) Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance, it should be understood that the applicant claims protection in respect of any patentable feature or combination of features referred to herein, and/or shown in the drawings, whether or not particular emphasis has been placed thereon.