U.S. patent application number 09/766769 was filed with the patent office on 2001-05-24 for wire bending apparatus.
Invention is credited to Benes, David, Kieffer, Vincent C., Kosch, Delmar D..
Application Number | 20010001368 09/766769 |
Document ID | / |
Family ID | 23760147 |
Filed Date | 2001-05-24 |
United States Patent
Application |
20010001368 |
Kind Code |
A1 |
Benes, David ; et
al. |
May 24, 2001 |
Wire bending apparatus
Abstract
A wire bending device includes an upright frame and a wire feed
hopper for dispensing wire rods. A wire bending section is mounted
on the frame, and at least one transport arm is pivotally mounted
on the frame, the transport arm operative to transport wire rods
from the hopper to the wire bending section. The wire bending
section includes a wire securement device mounted on the frame, the
rotatable wire securement device operative to secure one end of a
wire rod and rotate the wire rod about its longitudinal central
axis and a wire bending unit movably mounted on the frame. The wire
bending unit includes a wire bend head aligned with the center
longitudinal axis of the rotatable wire securement device, the wire
bending unit adapted to move on the frame such that the wire bend
head remains aligned with the center longitudinal axis of the
rotatable wire securement device. A control unit such as a
programmable computer is operatively connected to the transport
arm, the rotatable wire securement device and the wire bending unit
to engage the transport arm to transport a wire rod from the hopper
to the wire bending section, engage the rotatable wire securement
device to secure one end of the wire rod, move the wire bend head
to determined bend locations on the wire rod, rotate the wire rod
about its longitudinal central axis to programmed positions, and
engage the wire bend head to perform the programmed bend in the
wire rod.
Inventors: |
Benes, David; (Fremont,
NE) ; Kosch, Delmar D.; (Columbus, NE) ;
Kieffer, Vincent C.; (Osceola, NE) |
Correspondence
Address: |
ZARLEY MCKEE THOMTE VOORHEES & SEASE PLC
SUITE 3200
801 GRAND AVENUE
DES MOINES
IA
50309-2721
US
|
Family ID: |
23760147 |
Appl. No.: |
09/766769 |
Filed: |
January 22, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09766769 |
Jan 22, 2001 |
|
|
|
09443277 |
Nov 18, 1999 |
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Current U.S.
Class: |
72/306 |
Current CPC
Class: |
B21F 1/00 20130101 |
Class at
Publication: |
72/306 |
International
Class: |
B21D 011/00 |
Claims
We claim:
1. A wire bending device, comprising: an upright frame; and wire
bending means mounted on said frame; said wire bending means
including; a rotatable wire securement device mounted on said frame
and having a center longitudinal axis, said rotatable wire
securement device operative to secure one distal end of a wire rod
and rotate the wire rod about its longitudinal central axis; and a
wire bending unit movably mounted on said frame.
2. The wire bending device of claim 1 wherein said wire bending
means is comprised of a wire bend head aligned with said center
longitudinal axis of said rotatable wire securement device, said
wire bending unit adapted to move on said frame such that said wire
bend head remains aligned with said center longitudinal axis of
said rotatable wire securement device.
3. The wire bending device of claim 2 further comprising a wire
feed hopper for dispensing wire rods mounted on said frame.
4. The wire bending device of claim 3 wherein said wire feed hopper
is comprised of a holding bin, having at least a base wall and
opposite side walls, and a feed mechanism.
5. The wire bending device of claim 4 wherein said feed mechanism
is comprised of a generally cylindrical roller, having an outer
surface, that is rotatably adjustably mounted within said holding
bin, adjacent said base wall, such that the distance between the
outer surface of the roller and the base wall may be selectively
adjusted.
6. The wire bending device of claim 5 wherein said feed mechanism
is further comprised of a biasing mechanism, operatively connected
to said roller to force the roller toward said base wall and
selectively permit wire rods to pass between said roller and said
base wall.
7. The wire bending device of claim 6 wherein said feed mechanism
is further comprised of at least one wire receiving mechanism,
operatively and adjustably connected to said holding bin to hold
and position wire rods that pass between said roller and said base
wall.
8. The wire bending device of claim 3 further comprising at least
one transport arm pivotally mounted on said frame, said transport
arm including releasable wire holding means mounted thereon for
releasably holding a wire rod, said transport arm operative to
transport wire rods from said hopper to said wire bending
means.
9. The wire bending device of claim 4 further comprising a control
means operatively connected to said at least one transport arm,
said rotatable wire securement device and said wire bending unit,
said control means programmed to engage said at least one transport
arm to transport a wire rod from said hopper to said wire bending
means, engage said rotatable wire securement device to secure one
end of the wire rod, move said wire bending unit to designated
locations on the wire rod, rotate the wire rod about its
longitudinal central axis to programmed positions, and engage said
wire bend head to perform the programmed bend in the wire rod.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation application of Petitioners' earlier
application Ser. No. 09/443,277 filed Nov. 18, 1999, entitled WIRE
BENDING APPARATUS.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates to wire bending mechanisms
and, more particularly, to a unidirectional wire bending apparatus
which includes an air bladder wire securement mechanism which
secures a wire to be bent in a bending position, a
computer-controlled movably mounted bending unit having a bending
head travelling adjacent the wire for bending thereof, and a wire
rotation mechanism for rotating the wire so that as the bending
unit travels along the wire, the wire may be rotated to permit the
formation of three-dimensional bends in the wire.
[0004] 2. Description of the Prior Art
[0005] Various types of wire bending devices are found in the prior
art, and as the field of uses for bent wires has expanded, the
methods by which the various wire bending devices perform their
bending processes have become ever more sophisticated and
specialized. Wires are commonly used in many different
applications, such as car seats and the like, and for each
different seat type, a different bent wire is required to fit
within the seat. Therefore, the various wire bending units in the
prior art need to accommodate different bend patterns.
[0006] Some of the prior art devices include Nihashi U.S. Pat. No.
4,471,819 which discloses an apparatus for making a formed wire
which bends wire by holding it at its mid-point by a holder and
then consecutively bending the wire by a pair of movable bending
units which start at opposite ends of the wire and move towards the
center. As the bending units move along the wire, the wire is bent
to a desired angle. After a bend is performed, the wire is released
by the center clamp and held by clamps on each bending unit. The
wire is then rotated to its new position, the center clamp
reengages, and the bending units move to the next bending location.
Nihashi includes several inherent disadvantages, however, such as
the need for additional clamps and for the separate rotational
devices which slow the bending process. Furthermore, Nihashi is a
large machine, which will take up valuable shop floor space. There
is therefore a need for a wire bending device that remedies these
deficiencies.
[0007] Other prior art devices disclose wire bending devices that
are generally inefficient, requiring either manual insertion of
wires to be bent or bending devices which only permit
two-dimensional bending. There is therefore a need for a wire
bending device which is capable of feeding wires automatically into
the bending section of the device and which includes a wire
rotating device to permit the formation of three-dimensional bends
in the wire.
[0008] One common type of wire bending device includes a wire feed
which moves the wire past the bending head during the bending
process. A major problem encountered in the operation of these
devices is that the error tolerances for wire bends are often
smaller than the error margins of the machine, which means that
several pieces out of each production run will be unsuitable for
their intended use. The errors arise due to the motion of the wire
in different axes from the axis of movement of the wire, i.e.,
flexing of the wire during movement. To prevent this movement, many
of the prior art devices "thread" the wire through a guide hole
adjacent the bend head. Of course, while the bend head guide hole
will substantially eliminate the flexing of the wire, it also adds
a removal step to the bending process, which decreases the rate at
which wires will be produced and renders the device less efficient.
There is therefore a need for a wire bending device that holds the
wire in a stationary position during the bending process while the
bending head travels along the wire.
[0009] Another problem encountered in the prior art is that the
majority of bending devices support the wire above the bending
unit, which forces the operator of the device to remove the wire
from the machine after bending instead of the wire being released
to fall into a stocking bin or the like. Again, the inefficiencies
inherent in this design are obvious and there is a need for a
solution to this design flaw.
[0010] Therefore, an object of the present invention is to provide
an improved wire bending device.
[0011] Another object of the present invention is to provide a wire
bending device which will automatically feed wires to be bent into
the bending section of the device.
[0012] Another object of the present invention is to provide a wire
bending device which includes a bending head and a wire securement
device that rotates the wire to permit three-dimensional bending of
the wire.
[0013] Another object of the present invention is to provide a wire
bending device that is at least partially computer-controlled to
enable rapid resetting of bend positions in the wire and to allow
for multiple bend patterns to be accessed and used without
requiring resetting of the bend information.
[0014] Another object of the present invention is to provide a wire
bending device which includes a wire securement device such as an
air bladder actuated chuck that will hold a very short section of
the end of the wire to permit substantially the entire wire to be
bent.
[0015] Finally, an object of the present invention is to provide a
wire bending device which is relatively simple and sturdy in
construction and is safe and efficient in use.
SUMMARY OF THE INVENTION
[0016] The present invention provides a wire bending device which
includes an upright frame and a wire feed hopper for dispensing
wire rods, the hopper mounted on the frame. A wire bending section
is mounted on the frame, and at least one transport arm is
pivotally mounted on the frame, the transport arm including a
releasable wire holding device such as a magnet mounted thereon for
releasably holding a wire rod, the transport arm being operative to
transport wire rods from the hopper to the wire bending section of
the device. The wire bending section includes a rotatable wire
securement device mounted on the frame and having a center
longitudinal axis, the rotatable wire securement device operative
to secure one end of a wire rod and rotate the wire rod about its
longitudinal central axis and a wire bending unit movably mounted
on the frame, the wire bending unit including a wire bend head
aligned with the center longitudinal axis of the rotatable wire
securement device, the wire bending unit adapted to move on the
frame such that the wire bend head remains aligned with the center
longitudinal axis of the rotatable wire securement device. A
control unit such as a programmable computer is operatively
connected to the transport arm, the rotatable wire securement
device and the wire bending unit, the control unit programmed to
engage the transport arm to transport a wire rod from the hopper to
the wire bending section, engage the rotatable wire securement
device to secure one end of the wire rod, move the wire bend head
to determined bend locations on the wire rod and rotate the wire
rod about its longitudinal central axis to programmed positions,
and engage the wire bend head to perform the programmed bend in the
wire rod.
[0017] The present invention thus provides a substantial
improvement over those bending devices found in the prior art. For
example, many devices require manual insertion of wires to be bent
into the device, whereas the present invention automatically feeds
wires into the bending section. Furthermore, because the present
invention provides for rotation of the wire rod, three-dimensional
bends may be formed in the wire. Also, the precise controllable
positioning of the wire bend head greatly reduces the chances of
unusable wires being produced. Repeatability and consistency are
the hallmarks of the present invention, and thus it is seen that
the present invention is superior to those devices found in the
prior art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of the wire bending apparatus
of the present invention;
[0019] FIG. 2 is a front elevational view of the present
invention;
[0020] FIG. 3A is a partial end view illustrating the wire rod
being positioned prior to bending;
[0021] FIG. 3B is a bottom view of FIG. 3A;
[0022] FIG. 4A is a view similar to FIG. 3 except that the rod has
been bent 90.degree.;
[0023] FIG. 4B is a bottom view of FIG. 4A;
[0024] FIG. 5 is a partial perspective view of the invention;
[0025] FIG. 6 is a partial top elevational view of a portion of the
wire bending apparatus;
[0026] FIG. 7 is a partial perspective view illustrating the wire
rod having been bent 90.degree.;
[0027] FIG. 8 is a perspective view of a wire rod having been bent
several times;
[0028] FIG. 9 is a perspective view illustrating the bin for
storing the rods prior to their being bent;
[0029] FIG. 10 is a partial bottom perspective view of portions of
the invention;
[0030] FIG. 11 is a partial sectional view of the wire feeding
apparatus;
[0031] FIGS. 12A, 12B and 12C are sectional views illustrating the
sequential movement of a rod through the wire rod feeding
apparatus;
[0032] FIG. 13 is a perspective view of a portion of the invention;
and
[0033] FIG. 14 is a partial end view of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] The wire bending device 10 of the present invention is best
shown in FIGS. 1-5 as including an upright frame 12 having vertical
support beams 14a and 14b and upper horizontal support beam 16
extending between and connecting vertical support beams 14a and
14b. The base structure 18 of upright frame 12 which is shown in
FIGS. 1 and 2 may be constructed in various other manners so long
as the support functions of the base structure 18 are
fulfilled.
[0035] For clarity and to provide a better understanding of the
operation of the present invention, the description of the present
invention will follow the progress of a single wire rod 100 as it
is fed through the wire bending device 10 of the present invention.
Therefore, the present description begins with the wire rod 100
being positioned within the hopper 20, which is shown best in FIGS.
1-5. The hopper 20, in the preferred embodiment, would include a
large wire holding bin 22 having a width of approximately
forty-eight inches. Of course, the precise width of the bin 22 is
not critical to the present invention, so long as wire rods which
are to be bent by the wire bending device 10 are of smaller length
than the width of wire holding bin 22 to fit therewithin. The wire
rods stored within bin 22 would be stacked atop one another and
aligned generally parallel with each other within the wire holding
bin 22, the wire rods being removed from wire bin 22 by feed
mechanism 24 positioned adjacent the lower front of wire holding
bin 22, as shown best in FIG. 5. In the preferred embodiment, the
feed mechanism 24 would include a large cylindrical roller 26
mounted within wire holding bin 22 and adjustably spaced from base
28 of wire holding bin 22 such that the gap between the outer wall
of roller 26 and base wall 28 may be adjusted. It is preferred that
the forward end of base wall 28 be lower than the rear end of base
wall 28 such that wire rods within wire holding bin 22 will roll
forward to contact the outer wall of roller 26 as the outer wall of
cylindrical roller 26 at base wall 28 approach one another. It is
further preferred the cylindrical roller 26 be mounted on wire
holding bin 22 in connection with a biasing device 30 such as a
spring tension device. Biasing device 30 would act to force
cylindrical roller 26 downwards towards base wall 28 thus,
preventing the unintentional exit of wire rods from between
cylindrical roller 26 and base wall 28. When cylindrical roller 26
is rotated in a clockwise direction, the lowermost wire rod 100 is
engaged by the outer wall 27 of cylindrical roller 26 and pulled
forward due to frictional contact therewith. Because the diameter
of wire rod 100 is greater than the cap between cylindrical roller
26 and base wall 28, cylindrical roller 26 moves upwards slightly,
but continues to be biased downwards due to the effect of biasing
device 30 on cylindrical roller 26. In this manner, the feeding of
wire rods may be precisely controlled through the rotation of
cylindrical roller 26 specifically for the purpose of aligning the
rods in a single layer.
[0036] When wire rod 100 moves forward far enough to disengage from
cylindrical roller 26, wire rod 100 rolls forward down the slope of
base wall 28 to contact the second section of the feed mechanism
24, shown best in FIG. 5. The second section of feed mechanism 24
includes right and left rod-receiving mechanisms 32 and 34, right
rod-receiving mechanism 32 being mounted in a fixed position
adjacent the forward end of base wall 28 and left rod-receiving
mechanism 34 being adjustably mounted on a pair of slide bars 36a
and 36b which will permit the distance between right and left
rod-receiving mechanisms 32 and 34 to be adjusted. In this manner,
different lengths of wire rods may be received and positioned
correctly prior to being fed through the wire bending section of
the present invention. In the preferred embodiment, when a wire rod
100 rolls into contact with left and right rod-receiving mechanisms
32 and 34, wire rod lifters 35a and 35b lift the wire rod 100
upwards above wall plates 36a and 36b, and the wire rod 100 then
rolls forward on top of wall plates 36a and 36b until it is stopped
by a pair of wire retention arms 38a and 38b which are pivotally
mounted on the left and right rod-receiving mechanisms 32 and 34
whereby the wire rod 100 is supported in a feed-engaging position,
as best shown in FIG. 6. The wire rod 100 is thus ready for
transport from the hopper 20 to the wire bending section 40 of the
present invention.
[0037] To move the wire rod 100 from the hopper 20 to the wire
bending section 40 of the wire bending device 10 of the present
invention, a pair of pivoting wire feed arms 42a and 42b are
mounted on a rotating beam 44 mounted on base structure 18 of
upright beam 12. The rotation of rotating beam 44 is controlled by
an electric motor 46 mounted on upright frame 12, as shown best in
FIGS. 1 and 2, whereby wire feed arms 42a and 42b may be rotated
between a wire pick-up position adjacent hopper 20 and a wire feed
position adjacent wire bending section 40 of wire bending device
10. In the preferred embodiment, leftmost wire feed arm 42b would
be slidably adjustably mounted on rotating beam 44 to permit
adjustment of positioning of wire feed arm 42b to accommodate
variously sized wire rods. Mounted on the upper ends of each wire
feed arm 42a and 42b are proximity switches 48a and 48b and
electromagnets 50a and 50b, shown best in FIG. 2. As the wire feed
arms 42a and 42b are pivoted into wire receiving position adjacent
hopper 20, the proximity switches 48a and 48b signal that the arms
42a and 42b are in the correct position and stop the functioning of
electric motor 46 thereby ceasing rotation of rotating beam 44.
When the wire rod 100 is positioned within left and right
rod-receiving mechanisms 34 and 32, the wire rod 100 is supported
generally adjacent electromagnets 50a and 50b on the ends of wire
feed arms 42a and 42b. Current then flows through electromagnets
50a and 50b thus releasably securing wire rod 100 to the wire feed
arms 42a and 42b. At that same time, right and left rod-receiving
mechanisms 32 and 34 release wire rod 100 by wire retention arms
38a and 38b pivoting upwards to permit the wire rod 100 to be
transported to the wire bending section 40 of the present
invention. Once the wire rod is released by rod-receiving
mechanisms 32 and 34, electric motor 46 is engaged thus rotating
the rotating beam 44 in a counterclockwise direction and pivoting
wire feed arms 42a and 42b towards the wire bending section 40 of
the present invention. Proximity switches 48a and 48b recognize the
location of the wire bending section 40 and signal the electric
motor 46 to stop rotating the rotating beam 44 when the wire rod
100 is aligned with the wire bending section 40 of the present
invention. When rotation of rotating beam 44 ceases, the wire rod
100 is correctly positioned for securement within wire bending
section 40 of the present invention.
[0038] The wire bending section 40 of the present invention is
shown best in FIGS. 1-6 as including a wire securement mechanism 51
which receives the wire rod 100 held by electromagnets 50a and 50b
on wire feed arms 42a and 42b and secures the wire rod 100 in a
generally horizontal position below upper horizontal support beam
16 of upright frame 12. The wire securement mechanism 51, in the
preferred embodiment, includes a wire support sleeve 52 into which
the wire to be bent is inserted, the wire support sleeve 52
extending coaxially with the axis of rotation of the wire
rotational mechanism 80. The sleeve 52 accepts the wire therein
with the end of the wire seated only approximately one-eighth of an
inch (1/8") within the outer end of the sleeve 52, and the wire is
held within the sleeve 52 by a chuck 53 positioned within the
sleeve 52. The chuck is opened and closed by the inflation and
deflation of air bladder 54 which moves a shaft 57 within sleeve 52
which in turn expands or contracts the chuck to secure the wire
therewithin. Of course, various kinds of chucks may be used with
the present invention, each of which would be understood by one
skilled in the art, but it is important that any chuck used in the
invention be capable of securing the wire rod 100 using as short a
section of the rod as practicable. Because of the chuck, wires may
be quickly and easily inserted and removed from the sleeve 52 by
inflating and deflating the air bladder 54.
[0039] Rotation of the wire is accomplished by the wire rotational
mechanism 80 which, in the preferred embodiment, is a small wheel
82 connected by a belt 84 to the large wheel 86 concentrically
mounted on the wire securement mechanism 50. Wire securement
mechanism 51 is rotatably mounted on vertical support beam 14a by
bearings 55a and 55b such that wire securement mechanism 51 can be
rotated about the longitudinal axis of the wire being secured
therein, the rotation being done by the driving of small wheel 82
by means of a precision drive motor 88 or the like, thus turning
belt 84 and large wheel 86. The wire securement mechanism is thus
rotated to align the wire in the next bending position. It is
expected that the precision drive motor will be operatively
connected to a computer to accurately control the amount of
rotation of the wire to ensure precise bending of the wire, along
with efficient repeatability of the programmed bending
sequence.
[0040] The bending unit 101 is best shown in FIGS. 1 and 4 as
including a base plate assembly having a generally inverted
U-shaped slide plate 102 and a generally flat mounting plate 104
mounted on the slide plate 102. A cam support bar 106 extends
generally perpendicular from the mounting plate 104, the cam
support bar rotatably supporting a bending cam shaft 108 by bearing
collars 110a and 110b. Mounted on the base of cam shaft 108
concentrically therewith is a cylindrical pinion 112 which rotates
with cam shaft 108, pinion 112 intermeshing with movable rack 114.
Movable rack 114 is driven perpendicular to the pinion 112 to
rotate the pinion 112 and thus rotate the cam shaft 108. The rack
114 may be driven by any appropriate means, but it is preferred
that the rack 114 be forced outwards by a pneumatic or hydraulic
ram or the like. Mounted at the outward end of rack 114 is a
projecting rack bolt 115 which extends outward to contact bend stop
bolts, as will more clearly explained later in this disclosure.
[0041] The apparatus which actually bends the wire is referred to
generally as the wire bend head and includes a cam follower 116
which is mounted on the side of the cam shaft 108 adjacent the top
of the cam shaft 108 and a bend block 118 mounted on the cam
support bar 106 adjacent the top of the cam support bar 106. The
cam follower 116 rotates with the cam shaft 108 about bend block
118 to bend a wire extending therebetween about bend block 118, as
the axis of rotation of the cam shaft 108 is generally aligned with
the bend block 118, as shown in FIG. 4.
[0042] An alternative embodiment of the wire bend head is shown in
FIG. 5 in which the cam shaft 108 is replaced by a cam sleeve 130
which rotates about an upright non-rotating bend head support shaft
132 extending upwards from mounting plate 104. On top of the
support shaft 132 is the bend head 134 through which the wire to be
bent extends. A cam follower 136 similar to the one described in
connection with FIG. 4 is mounted on sleeve 130, and operates in a
similar manner, i.e., rotating about the bend head 134 to bend the
wire. One improvement permitted by this arrangement is that the
bend head 134 may be quickly and easily switched to accommodate a
new size of wire. The degree of bend of the wire is determined by
the distance through which the rack 114 travels, thereby rotating
the cam shaft 108 and thus cam follower 116. Also, the location of
the bend made in the wire is determined by the location of the
bending unit 101 along the wire. The positioning apparatus 150 for
controlling the positioning of the bending unit 101 along the wire
rod 100 is best shown in FIG. 2 as including a slide track 152 over
which slide plate 102 fits, the slide track 152 permitting movement
of the bending unit 101 parallel to the wire to be bent. There are
two current best modes of moving the bending unit 101 along slide
track 152, and these are by means of a rodless air cylinder 154
(shown in FIG. 1) or by means of an electric motor 156 mounted on
the bending unit 101 which is connected to a gear 158 which
intermeshes with a track 160 (shown in FIG. 2). Of course, it
should be noted that any appropriate type of precisely controllable
movement device may be substituted for those described above, such
as a rack and pinion or mounting of the bending unit 101 on a
movable rotating belt which extends along the table 12.
[0043] The two movement devices each operate in their understood
manner, with the location of the bends in the wire being determined
by the following system, which is shown best in FIGS. 3-6 in the
preferred embodiment. Mounted on the forward portion of the
mounting plate 104 are two proximity switches 163a and 163b,
proximity switch 163a positioned slightly closer to said wire
securement mechanism 51 than proximity switch 163b such that as
said bending unit 101 moves towards the wire securement mechanism
51, proximity switch 163a encounters the stop/bend points before
proximity switch 163b. A plurality of stop/bend collars 164a, 164b,
164c, 164d, 164e and 164f are adjustably mounted on a slide bar 168
mounted on the frame 12 forward of the slide track 160, as shown
best in FIGS. 2 and 6. The horizontal position of each of the
stop/bend collars 164a-f may thus be adjusted to signify bend
points on the wire rod 100. As the bending unit 101 moves towards
the wire securement mechanism 51, the speed of movement of the
bending unit 101 is fast until proximity switch 163a signals the
control unit 180 that the next stop/bend collar in line has been
reached. The travel speed of the bending unit 101 is then
immediately slowed and the bending unit moves at a reduced rate of
speed until proximity switch 163b signifies that the bend location
has been reached. Proximity switch 163b is positioned on the
bending unit 101 such that the proximity switch 163b is aligned
with the stop/bend collar when the bending unit 101 is in the
precise location for the bend to be performed, thus permitting the
bend to be formed in the wire rod 100 at the exact location
determined by the operator.
[0044] Each of the stop/bend collars 164a-f include an inwardly
extending, length-adjustable bend stop bolt 166a-f that extends
inwards towards slide track 160, the bend stop bolts 166a-f
positioned to impede the outward motion of rack 114 by receiving
contact from the projecting rack bolt 115. The distance through
which the rack 114 travels is determined by the bend stop bolts
166a-f. When the rack 114 is moved towards slide bar 168, thereby
rotating the cam shaft 108, the movement of the rack 114 is stopped
when projecting rack bolt 115 butts against the adjacent bend stop
bolt 166a-f. The direction of rack movement then reverses and the
bending unit is readied for the next bend to be made. By adjusting
the length of the bend stop bolts 166a-f, the point at which the
projecting rack bolt 115 contacts each bolt is changed, and thus
the length of travel of the rack 114 is modified. If the rack 114
moves a greater distance, the degree of bend formed in the wire
being bent is greater, and vice versa. Therefore, when the movable
rack 114 is forced to move, pinion 112 and cam shaft 108 rotate
thereby rotating cam follower 116 about bend block 118 thus forming
a bend in the wire rod 100 extending from wire securement mechanism
50. Once the rack 114 has returned to its starting location, the
control unit 180 senses this and engages the rodless air cylinder
154 or electric motor 156 to move the bending unit 101 to the next
stop/bend collar 164a-f. Once all of the stop/bend collars 164a-f
for the particular bend pattern have been encountered by the
bending unit 101, the now bent wire rod 100 is released from the
wire securement device 51 and the process begins anew.
[0045] The control unit 180 of the present invention is preferably
a programmed computer which performs the functions coordinating the
functioning of the invention. Specifically, the control unit 180
would initiate cylindrical roller 26 to feed a wire rod 100 to
right and left rod-receiving mechanisms 32 and 34 which position
wire rod 100 for transfer to the wire bending section 40. Electric
motor 46 would then be engaged thus rotating the rotating beam 44
in a counterclockwise direction and pivoting wire feed arms 42a and
42b towards the wire bending section 40 of the present invention.
Proximity switches 48a and 48b recognize the location of the wire
bending section 40 and signal the electric motor 46 to stop
rotating the rotating beam 44 when the wire rod 100 is aligned with
the wire bending section 40 of the present invention. When rotation
of rotating beam 44 ceases, the wire rod 100 is correctly
positioned for securement within wire bending section 40 of the
present invention.
[0046] The control unit 180 then signals wire securement device 51
to secure the wire rod 100 in wire bending position and engages the
wire bending unit 101 to commence bending. As each positioned
stop/bend collar 164a-f is reached, the proximity switches 163a and
163b signal the control unit 180 of the location of the wire
bending unit 101, and the control unit 180 stops the movement of
the wire bending unit 101 at the correct location for the bend to
be made. After the bend is made in the wire rod 100, the control
unit engages the rodless air cylinder 154 or electric motor 156 to
move the bending unit 101 to the next bend location.
Simultaneously, the control unit 180 rotates the wire rod 100
through engagement of the wire rotational mechanism 80 to the
programmed alignment for the next bend in the bending sequence.
Finally, when all of the bends of the wire rod 100 have been
performed, the control unit signals the wire securement device 51
to release the wire rod 100 and the next wire rod is moved into
position for bending.
[0047] The other primary function of the control unit 180 is to
count the number of wires produced during the production run and to
deactivate the wire bending device 10 upon reaching the preset
production run number. This feature helps to lessen the tasks of
the operator and permit the operator to be more efficient in
production.
[0048] When taken as a whole, it is seen that a limitless number of
types of bends in wires may be made by the present invention. By
adding or subtracting stop/bend collars 164a-f the number of bends
made in the wire can be precisely set, and by programming the
control unit 180 to initiate rotation of the wire by means of the
wire rotational mechanism 80 after a bend is made, the precise
shape of the wire being bent can be controlled.
[0049] It is to be understood that numerous modifications,
additions and substitutions may be made to the wire bending device
10 of the present invention which fall within the intended broad
scope of the disclosure of this invention. For example, the size,
shape and arrangement of the features of the present invention may
be modified and changed so long as the functionality of the
invention is maintained. Furthermore, the drive mechanisms for the
various elements of the present invention may be replaced with
other mechanisms found in the art, so long as the precise location
control features are maintained. Finally, although the present
invention has been described as including a wire transport device
including transport arms, it is entirely feasible that alternative
constructions would perform the transport tasks equally as
well.
[0050] There has thus been shown and described a wire bending
device which accomplishes at least all of the stated
objectives.
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