US20080289389A1 - Wire-forming apparatus - Google Patents
Wire-forming apparatus Download PDFInfo
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- US20080289389A1 US20080289389A1 US12/127,582 US12758208A US2008289389A1 US 20080289389 A1 US20080289389 A1 US 20080289389A1 US 12758208 A US12758208 A US 12758208A US 2008289389 A1 US2008289389 A1 US 2008289389A1
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- wire
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21F—WORKING OR PROCESSING OF METAL WIRE
- B21F1/00—Bending wire other than coiling; Straightening wire
- B21F1/04—Undulating
Definitions
- the present invention relates to a forming device and method.
- the forming device is configured to form a relatively straight wire into a periodic shape, such as a sinusoidal shape.
- forming devices have utilized a gear or teeth to shape a generally straight wire into a sinusoidal shape. Because there are limitations to such approaches, there is a need for the present invention.
- FIG. 1 illustrates a perspective view of one embodiment of a forming device in accordance with one embodiment.
- FIG. 2 illustrates a top view of a forming station of one embodiment of a forming device in accordance with one embodiment.
- FIG. 3 a illustrates a plurality of forms in a forming station of a forming device in accordance with one embodiment.
- FIG. 3 b illustrates a segment of a wire formed in the forming station of a forming device in accordance with one embodiment.
- FIGS. 4 a - 4 i illustrates a plurality of forms during a sequence of forming a wire in accordance with one embodiment.
- FIGS. 5 a - 5 i illustrates a plurality of forms during a sequence of forming a wire in accordance with one embodiment.
- FIG. 6 illustrates a segment of a wire formed in the forming station of a forming device in accordance with one embodiment.
- FIG. 7 illustrates a perspective top view of a forming station of one embodiment of a forming device in accordance with one embodiment.
- FIG. 8 illustrates a plurality of forms in a forming station of a forming device in accordance with one embodiment.
- FIG. 1 illustrates a perspective view of forming device 10 in accordance with one embodiment.
- forming device 10 includes an input 12 , a forming station 14 and an output 16 .
- a spool 22 holds wire 20 that is in an unformed state 20 a at input 12 .
- Wire 20 is then fed into forming station 14 and is formed such that it comes out in a formed state 20 b in output 16 .
- wire 20 in an unformed state 20 a is generally straight, and in a formed state 20 b is generally periodic.
- Output 16 includes a tray 50 into which wire 20 in a formed state 20 b is fed from forming station 14 .
- An orientation axis is given in the figure to illustrate x, y, and z-axes.
- forming station 14 includes first, second, third and fourth actuated blocks 41 , 42 , 43 and 44 .
- Corresponding to each actuated block 41 - 44 is first, second, third and fourth forms 31 , 32 , 33 and 34 (illustrated in FIG. 2 ).
- each of first, second, third and fourth actuated blocks 41 , 42 , 43 and 44 is coupled to one of first, second, third and fourth forms 31 , 32 , 33 and 34 and aligned such that they are perpendicular to wire 20 as wire 20 moves from input 12 to output 16 along the x-axis.
- first through fourth actuated blocks 41 - 44 and thus first through fourth forms 31 - 34 , are actuated along the y-axis.
- FIG. 2 illustrates a top view of a forming station 14 in accordance with one embodiment.
- First, second, third and fourth forms 31 , 32 , 33 and 34 are respectively coupled to first, second, third and fourth actuated blocks 41 , 42 , 43 and 44 .
- first, second, third and fourth actuated blocks 41 , 42 , 43 and 44 are seated on first, second, third and fourth rails 51 , 52 , 53 and 54 .
- the x and y-axes are illustrated, and the z-axis would extend out of the page.
- wire 20 is illustrated moving in the x-axis, or passing from right-to-left as viewed in the figure, such that it is in an unformed state 20 a entering forming station 14 on the right side and such that it is in a formed state 20 b exiting forming station 14 on the left side.
- first through fourth actuated blocks 41 - 44 and first through fourth forms 31 - 34 move independently and in timed sequence in the y-axis toward and away from wire 20 such that forms 31 - 34 bend wire 20 .
- Wire 20 exits forming station 14 in a formed state 20 b , which in one embodiment, is substantially of a sinusoidal shape.
- first-fourth blocks 41 - 44 are actuated toward and away from wire 20 along first-fourth rails 51 - 55 , which also lie along the y-axis.
- Forming station 14 can include a variety of mechanisms that move blocks 41 - 44 , and thus forms 31 - 34 that are coupled thereto, toward and away from wire 20 in to bend it into a formed state 20 b .
- each of first-fourth blocks 41 - 44 on first-fourth rails 51 - 55 can be coupled to, and actuated by, a solenoid that moves each block 41 - 44 linearly perpendicular to wire 20 .
- a pneumatic device can be coupled to each of blocks 41 - 44 to actuate blocks 41 - 44 and forms 31 - 34 toward and away from wire 20 as wire 20 is moved through forming station 14 .
- Other embodiments include other means of moving the blocks 41 - 44 and forms 31 - 34 toward and away from wire 20 .
- FIG. 3 a illustrates a portion of first through fourth forms 31 - 34 of a forming station 14 in accordance with one embodiment.
- each of first through fourth forms 31 - 34 respectively include first through fourth forming points 36 - 39 .
- forms 31 - 34 and associated forming points 36 - 39 engage wire 20 as they are moved toward and away from wire 20 as wire is moved through forming station 14 in the direction indicated by arrow 25 , wire 20 is bent from its unformed state 20 a into its formed state 20 b.
- each of forms 31 - 34 and forming points 36 - 39 are illustrated as extended fully “in” toward wire 20 such that a space or forming zone 35 is left between the collective group of forming points 36 - 39 .
- the width of forming zone 35 generally matches the width of wire 20 .
- wire 20 is bent from its unformed state 20 a by forming points 36 - 39 so that its formed state 20 b is generally similar to the shape of forming zone 35 .
- Forming points 36 - 39 can be configured in a variety of ways to create a variety of shapes for forming zone 35 , and thus for formed state 20 b of wire 20 .
- forming zone 35 has a sinusoidal shape defining an amplitude (Y 35 ) and a wavelength ( ⁇ 35 ).
- Y 35 amplitude
- ⁇ 35 wavelength
- forming points 36 - 39 are moved toward and away from wire 20 .
- formed state 20 b of wire 20 can be a continuous sinusoidal shape.
- FIG. 3 b illustrates a segment of wire 20 in a formed state 20 b that is formed in a forming station 14 in accordance with one embodiment.
- wire 20 is bent from its unformed state 20 a by forming points 36 - 39 to generally be similar to the shape of forming zone 35 , such that wire 20 in a formed state 20 b has an amplitude (Y 20 ) and has a wavelength ( ⁇ 20 ).
- the respective amplitudes (Y 35 and Y 20 ) and wavelengths ( ⁇ 35 and ⁇ 20 ) of forming zone 35 and wire 20 in a formed state 20 b can be similar, but are not necessarily identical.
- wire 20 has some spring-back associated with it such that wire 20 in a formed state 20 b has an amplitude (Y 20 ) that is slightly smaller than the amplitude (Y 35 ) of forming zone 35 and has a wavelength ( ⁇ 20 ) that is slightly longer than the wavelength ( ⁇ 35 ) of forming zone 35 .
- wire 20 is a metal, such as a cobalt based superalloy.
- FIGS. 4-5 illustrate first through fourth forms 31 - 34 and first through fourth forming points 36 - 39 independently and sequentially moving toward and away from wire 20 as it moves from input 12 to output 16 through forming station 14 , thereby bending wire 20 into a formed state 20 b .
- FIG. 3 b illustrates a portion of wire 20 into its formed state 20 b that is formed using the processes illustrated in FIGS. 4-5 .
- FIG. 4 illustrates an initiation of a process starting with a wire 20 that is completely in an unformed state 20 a as the process begins. In the example, it is referred to as initial wire processing.
- FIG. 5 illustrates subsequent processing where at least some bending of wire 20 has already occurred as the process begins. In the example, it is referred to as subsequent wire processing.
- FIG. 4 a illustrates wire 20 entering first through fourth forms 31 - 34 in forming station 14 in an unformed state 20 a , such as from input 12 .
- Output 16 is referenced to the left in the figure. In one embodiment, this illustrates the initial wire processing for bending wire 20 .
- fourth form 34 is illustrated “in” toward wire 20
- first through third forms 31 - 33 are illustrated “out” away from wire 20 .
- first form 31 is illustrated actuated in toward wire 20 .
- Fourth form 34 remains in and second and third forms 32 - 33 remain out. As first form 31 is actuated in, wire 20 is moved by the impact of first forming point 36 against wire 20 .
- second form 32 is illustrated actuated in toward wire 20 .
- First and fourth forms 31 and 34 remain in and third form 33 remains out.
- wire 20 is bent from its unformed state 20 a by the combined impact of first and second forming points 36 and 37 against wire 20 .
- fourth form 34 is illustrated actuated out away from wire 20 .
- First and second forms 31 and 32 remain in and third form 33 remains out.
- third form 33 is illustrated actuated in toward wire 20 .
- First and second forms 31 and 32 remain in and fourth form 34 remains out.
- wire 20 is bent from its unformed state 20 a by the combined impact of second and third forming points 37 and 38 against wire 20 .
- fourth form 34 remains out at that point in time, wire 20 is allowed to move on the side of input 12 .
- only approximately one half of a single wavelength ( ⁇ 20 ) of wire 20 is bent at one time from an unformed state 20 a to a formed state 20 b .
- a single wavelength ( ⁇ 20 ) of wire 20 is constrained between forming points 36 , 37 and 38 of first, second and third forms 31 - 33 .
- first form 31 is illustrated actuated out away from wire 20 .
- Second and third forms 32 and 33 remain in and fourth form 34 remains out.
- fourth form 34 is illustrated actuated in toward wire 20 .
- Second and third forms 32 and 33 remain in and first form 31 remains out.
- wire 20 is bent from its unformed state 20 a by the combined impact of third and fourth forming points 38 and 39 against wire 20 .
- ⁇ 20 single wavelength
- a single wavelength ( ⁇ 20 ) of wire 20 is constrained between forming points 37 , 38 and 39 of second, third and fourth forms 32 - 34 .
- second form 32 is illustrated actuated out away from wire 20 .
- Third and fourth forms 33 and 34 remain in and first form 31 remains out.
- third form 33 is also illustrated actuated out away from wire 20 .
- First and second forms 31 and 32 remain out, while only fourth form 34 remains in.
- FIGS. 5 a - 5 i illustrate one embodiment of such subsequent wire processing.
- wire 20 in FIG. 5 a is indexed slightly toward output 16 .
- a first wavelength ( ⁇ 20 ) in wire 20 i.e., that portion of wire 20 that transitions from “up” to “down” to “up” again, as viewed in FIG. 4i
- wire 20 is indexed toward output 16 by one wavelength ( ⁇ 20 ) such that that same wavelength ( ⁇ 20 ) is now moved past forming point 36 of form 31 on the side of output 16 .
- first form 31 is illustrated actuated in toward wire 20 .
- Fourth form 34 remains in and second and third forms 32 - 33 remain out.
- second form 32 is illustrated actuated in toward wire 20 .
- First and fourth forms 31 and 34 remain in and third form 33 remains out.
- first form 31 is actuated in, a previously bent portion of wire 20 is secured by first and second forming points 36 and 37 against wire 20 .
- fourth form 34 is illustrated actuated out away from wire 20 .
- Third form 33 remains out and first and second forms 31 and 32 remain in securing wire 20 .
- third form 33 is illustrated actuated in toward wire 20 .
- First and second forms 31 and 32 remain in and fourth form 34 remains out.
- wire 20 is bent from its unformed state 20 a by the combined impact of second and third forming points 37 and 38 against wire 20 .
- fourth form 34 remains out at that point in time, wire 20 is allowed to move on the side of input 12 .
- only approximately one half of a single wavelength ( ⁇ 20 ) of wire 20 is bent at one time from an unformed state 20 a to a formed state 20 b .
- a single wavelength ( ⁇ 20 ) of wire 20 is constrained between forming points 36 , 37 and 38 of first, second and third forms 31 - 33 .
- first form 31 is illustrated actuated out away from wire 20 .
- Second and third forms 32 and 33 remain in and fourth form 34 remains out.
- fourth form 34 is illustrated actuated in toward wire 20 .
- Second and third forms 32 and 33 remain in and first form 31 remains out.
- wire 20 is bent from its unformed state 20 a by the combined impact of third and fourth forming points 38 and 39 against wire 20 .
- ⁇ 20 single wavelength
- a single wavelength ( ⁇ 20 ) of wire 20 is constrained between forming points 37 , 38 and 39 of second, third and fourth forms 32 - 34 .
- second form 32 is illustrated actuated out away from wire 20 .
- Third and fourth forms 33 and 34 remain in and first form 31 remains out.
- third form 33 is also illustrated actuated out away from wire 20 .
- First and second forms 31 and 32 remain out, while only fourth form 34 remains in.
- wire 20 is not impinged by them and can be readily moved or indexed for additional subsequent wire processing.
- Wire 20 in its formed state 20 b has sinusoidal shape with an amplitude (Y 20 ), and is generally flat along the z-axis (the dimension coming out of the page as viewed in FIGS. 2 , 3 a and 3 b , for example).
- first and second forms 31 and 32 when first and second forms 31 and 32 are transitioned in, they are configured to hold or constrain wire 20 in its formed state. This is illustrated, for example, in FIG. 5 e where first and second forms 31 and 32 are constraining wire 20 .
- third and fourth forms 33 and 34 are transitioned in, they are configured to engage wire 20 in its unformed state 20 and bend it into its formed state 20 b . This is illustrated, for example, in FIG. 5 e , where third form 33 bends wire 20 from its unformed state 20 to its formed state 20 b , and in FIG. 5 g , where fourth form 34 bends wire 20 from its unformed state 20 to its formed state 20 b .
- third form 33 also constrains wire 20 after it has been bent in order for fourth form 34 to accurately bend wire 20 .
- the wavelength ( ⁇ 20 ) of wire 20 is significantly less than the amplitude (Y 20 ) of wire 20
- bending an entire wavelength ( ⁇ 20 ) or more of wire 20 from an unformed state 20 a to a formed state 20 b at one time with forming points 36 - 39 can cause the formed state 20 b to be a distorted sinusoidal shape, of even cause wire 20 to brake or fracture.
- wire 20 has a diameter of four thousandths of one inch (0.004 inch). In other embodiments, wire 20 has a diameter as small as one half of one thousandths of one inch (0.0005), and in others it is as large as ten thousandths of one inch (0.010 inch). Also, a single wavelength ( ⁇ 20 ) of wire 20 created by forming points 36 - 39 is approximately twenty-four thousandths of one inch (0.024 inch), while the amplitude (Y 20 ) of wire 20 in its formed state 20 b is and approximately forty thousandths of one inch (0.040 inch).
- wire 20 With these fairly small dimensions, and with this ratio of amplitude (Y 20 ) to wavelength ( ⁇ 20 ), wire 20 is fairly easily bent, and if a full wavelength ( ⁇ 20 ) or more is bent from an unformed state 20 a to a formed state 20 b at one time, the sinusoidal formed state 20 b illustrated in FIG. 3 a will not be achieved.
- amplitude (Y 20 ) of wire 20 in its formed state 20 b is significantly larger than a single wavelength ( ⁇ 20 ) of formed wire 20 , as illustrated in FIG. 3 b , bending a relatively small diameter into a sinusoidal shape cannot effectively be achieved with a gear or tooth-type mechanism, which would effectively bend an entire wavelength ( ⁇ 20 ) of wire 20 over a tooth of the gear.
- a formed wire 20 b has a sinusoidal shape where a single wavelength ( ⁇ 20 ) of wire 20 is approximately fifty percent (50%) of the amplitude (Y 20 ), while in another example it is approximately sixty percent (60%) and in yet another it is ninety percent (90%).
- the length of forming points 36 - 39 (as illustrated in FIG. 3 ) can be readily adjusted to create these various proportions.
- each of forms first through fourth forms 31 - 34 are configured for independent actuation such that they move independently and consecutively in and out of a forming zone 35 , for example moving along rails 51 - 54 .
- the distance that forms 31 - 34 are actuated toward wire 20 can readily be adjusted during the forming process by regulating the distance of travel along rails 51 - 54 .
- the amplitude (Y 20 ) of the formed state 20 b can be adjusted.
- the amplitude (Y 20 ) of the formed state 20 b is adjusted during the forming process such that the overall amplitude (Y 20 ) of the formed state 20 b of wire 20 varies over its length.
- the wavelength ( ⁇ 20 ) of wire 20 can be adjusted. This is particularly true in the tapered region to accommodate for the slightly different wavelength produced at different amplitudes.
- FIG. 6 illustrates one example of a wire 20 in a formed state 20 b that has been formed with an amplitude (Y 20 ) that varies over its length.
- Y 20 an amplitude
- the amplitude (Y 20max ) is at a maximum and toward the ends of the portion the amplitude (Y 20min ) is at a minimum.
- the amplitude can be adjusted in various ways to achieve a wire in a formed state 20 b having various tapered forms.
- the indexing or moving a wire 20 through forming station 14 along the x-axis is done mechanically by physically moving wire 20 by one wavelength ( ⁇ 20 ), as described and illustrated above in the transition from FIG. 4 i to FIG. 5 a .
- this indexing of wire 20 can be achieved automatically with forming device 10 .
- FIG. 7 illustrates a portion of forming station 14 for forming device 10 in accordance with one embodiment.
- Forming station 14 includes first through fourth forms 31 - 34 , wire guide 28 and index pin 29 .
- Wire guide 28 includes slot 28 a .
- wire 20 in an unformed state 20 a enters forms first through fourth forms 31 - 34 and exits in a formed state 20 b.
- wire 20 is bent from its unformed state 20 a to its formed state 20 b with first through fourth forms 31 - 34 in accordance with the process described relative to FIGS. 4 a - 4 i and/or 5 a - 5 i .
- forming station 14 is configured with a wire guide 28 , which in one example is configured to direct wire 20 in its formed state 20 b toward guide pin 29 .
- wire guide 28 is configured with slot 28 a , into which wire 20 moves in its formed state 20 b .
- FIG. 7 a portion of wire 20 that has entered slot 28 a and is inside guide 28 is illustrated in dotted lines.
- Guide pin 29 is configured to be actuated along the z-axis, or in and out of the page as presented in FIG. 7 .
- guide 28 is configured with a cylindrical bore that receives guide pin 29 so that guide pin 29 can be actuated up or away from guide slot 28 a so that wire 20 in its formed state 20 b can travel under guide pin 29 within slot 28 a . Then, guide pin can be actuated down or toward guide slot 28 a so that wire 20 in its formed state 20 b can be pinned within guide slot 28 a by guide pin 29 , thereby holding wire 20 in place.
- guide 28 and guide pin 29 are moveable along the x-axis relative to first through forms 31 - 34 .
- guide 28 and guide pin 29 can be used to index wire 20 relative to first through fourth forms 31 - 34 .
- guide 28 and guide pin 29 are in a “back” position toward output 16 along the x-axis.
- Guide pin 29 is initially “up” (along the z-axis) and away from guide slot 28 a such that wire 20 can move freely in slot 28 a . Then, guide pin 29 is actuated “down” (along the z-axis) to hold the wire in place.
- wire 20 is formed in accordance with the process described in FIGS. 4 a - 4 i and/or 5 a - 5 i .
- guide pin 29 is actuated “up”.
- guide 28 and guide pin 29 are moved to a “forward” position toward input 12 along the x-axis.
- guide pin 29 moves downward (along the z-axis) to clamp or hold wire 20 within guide slot 28 a.
- first through forms 31 - 34 move out away from wire 20 (along the y-axis).
- Guide 28 and guide pin 29 are then moved back toward output 16 approximately one wavelength along the x-axis.
- First and second forms 31 - 32 then move in toward wire 20 (along the y-axis) and hold wire 20 , then third and forth forms 33 - 34 actuate to bend another portion of wire 20 . This process can then be repeated to continually index and bend wire 20 .
- first through forth forms 31 - 34 can be movable along the x-axis in addition to along the y-axis. In this way, the forms themselves can be used to index wire 20 .
- rails similar to rails 51 - 54 in FIG. 2 could extend along the x-axis and allow first through forth forms 31 - 34 to be actuated in that direction as well.
- guide 28 is stationary in all x-, y- and z-axis axes
- guide pin 29 is stationary in the x- and y-axes, while moving in the z-axis.
- Guide pin 29 starts out in the “down” position.
- Wire 20 is formed in accordance with the process described in FIGS. 4 a - 4 i and/or 5 a - 5 i .
- first and second forms 31 and 32 are transitioned in toward wire 20 (along the y-axis), while third and forth forms 33 and 34 are transitioned out away from wire 20 (along the y-axis).
- Guide pin 29 is then actuated “up” (along the z-axis).
- first and second forms 31 and 32 are then moved back toward output 16 approximately one wavelength along the x-axis.
- Guide pin 29 then moves downward (along the z-axis) to clamp or hold wire 20 against guide 28 within guide slot 28 a .
- first and second forms 31 and 32 are transitioned out away wire 20 (along the y-axis). Then, first and second forms 31 and 32 are moved to forward toward input 12 approximately one wavelength along the x-axis (back to the position from which they came).
- first and first and second 31 and 32 are transitioned in toward wire 20 along the y-axis to hold the part.
- third and fourth forms 33 and 34 can continue to bend wire 20 in accordance with the process described in FIGS. 4 a - 4 i and/or 5 a - 5 i .
- Guide pin 29 is then retracted from guide slot 28 a , and this process can then be repeated to continually index and bend wire 20 .
- FIG. 8 illustrates a portion of first through fourth forms 71 - 74 of a forming station 14 in accordance with one embodiment.
- each of first through fourth forms 71 - 74 respectively include forming points.
- the forming points further include features or grooves that give a forming zone 75 a modified sinusoidal shape.
- wire 20 bent in forming zone 75 will have a periodic shape, it will not be a true sinusoidal shape.
- Forming zone 75 has a modified sinusoidal shape defining an amplitude (Y 75 ) and a wavelength ( ⁇ 75 ).
- Y 75 amplitude
- ⁇ 75 ⁇ 75
- the forms can include other features, or may even be slanted slightly to produce “tilted” sinusoidal formed wires.
Abstract
Description
- This patent application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 60/940,305 entitled “WIRE FORMING DEVICE AND PROCESS,” having a filing date of May 25, 2007, the contents of which are incorporated herein by reference.
- The present invention relates to a forming device and method. In one embodiment, the forming device is configured to form a relatively straight wire into a periodic shape, such as a sinusoidal shape. In some cases forming devices have utilized a gear or teeth to shape a generally straight wire into a sinusoidal shape. Because there are limitations to such approaches, there is a need for the present invention.
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FIG. 1 illustrates a perspective view of one embodiment of a forming device in accordance with one embodiment. -
FIG. 2 illustrates a top view of a forming station of one embodiment of a forming device in accordance with one embodiment. -
FIG. 3 a illustrates a plurality of forms in a forming station of a forming device in accordance with one embodiment. -
FIG. 3 b illustrates a segment of a wire formed in the forming station of a forming device in accordance with one embodiment. -
FIGS. 4 a-4 i illustrates a plurality of forms during a sequence of forming a wire in accordance with one embodiment. -
FIGS. 5 a-5 i illustrates a plurality of forms during a sequence of forming a wire in accordance with one embodiment. -
FIG. 6 illustrates a segment of a wire formed in the forming station of a forming device in accordance with one embodiment. -
FIG. 7 illustrates a perspective top view of a forming station of one embodiment of a forming device in accordance with one embodiment. -
FIG. 8 illustrates a plurality of forms in a forming station of a forming device in accordance with one embodiment. - In the following Detailed Description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the Figure(s) being described. Because components of embodiments of the present invention can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.
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FIG. 1 illustrates a perspective view of formingdevice 10 in accordance with one embodiment. InFIG. 1 , formingdevice 10 includes aninput 12, a formingstation 14 and anoutput 16. In one embodiment, aspool 22 holdswire 20 that is in anunformed state 20 a atinput 12.Wire 20 is then fed into formingstation 14 and is formed such that it comes out in a formedstate 20 b inoutput 16. In one embodiment,wire 20 in anunformed state 20 a is generally straight, and in a formedstate 20 b is generally periodic.Output 16 includes atray 50 into whichwire 20 in a formedstate 20 b is fed from formingstation 14. An orientation axis is given in the figure to illustrate x, y, and z-axes. - In one embodiment, forming
station 14 includes first, second, third and fourth actuatedblocks fourth forms FIG. 2 ). In one case, each of first, second, third and fourth actuatedblocks fourth forms wire 20 moves frominput 12 to output 16 along the x-axis. In one embodiment, first through fourth actuated blocks 41-44, and thus first through fourth forms 31-34, are actuated along the y-axis. -
FIG. 2 illustrates a top view of a formingstation 14 in accordance with one embodiment. First, second, third andfourth forms blocks blocks fourth rails - In
FIG. 2 ,wire 20 is illustrated moving in the x-axis, or passing from right-to-left as viewed in the figure, such that it is in anunformed state 20 a entering formingstation 14 on the right side and such that it is in a formedstate 20 b exiting formingstation 14 on the left side. In formingstation 14, first through fourth actuated blocks 41-44 and first through fourth forms 31-34 move independently and in timed sequence in the y-axis toward and away fromwire 20 such that forms 31-34bend wire 20.Wire 20exits forming station 14 in a formedstate 20 b, which in one embodiment, is substantially of a sinusoidal shape. - In one embodiment, first-fourth blocks 41-44 are actuated toward and away from
wire 20 along first-fourth rails 51-55, which also lie along the y-axis. Formingstation 14 can include a variety of mechanisms that move blocks 41-44, and thus forms 31-34 that are coupled thereto, toward and away fromwire 20 in to bend it into a formedstate 20 b. For example, each of first-fourth blocks 41-44 on first-fourth rails 51-55 can be coupled to, and actuated by, a solenoid that moves each block 41-44 linearly perpendicular to wire 20. Similarly, a pneumatic device can be coupled to each of blocks 41-44 to actuate blocks 41-44 and forms 31-34 toward and away fromwire 20 aswire 20 is moved through formingstation 14. Other embodiments include other means of moving the blocks 41-44 and forms 31-34 toward and away fromwire 20. -
FIG. 3 a illustrates a portion of first through fourth forms 31-34 of a formingstation 14 in accordance with one embodiment. In one example, each of first through fourth forms 31-34 respectively include first through fourth forming points 36-39. As forms 31-34 and associated forming points 36-39 engagewire 20 as they are moved toward and away fromwire 20 as wire is moved through formingstation 14 in the direction indicated byarrow 25,wire 20 is bent from itsunformed state 20 a into its formedstate 20 b. - In
FIG. 3 a, each of forms 31-34 and forming points 36-39 are illustrated as extended fully “in” towardwire 20 such that a space or formingzone 35 is left between the collective group of forming points 36-39. In the illustration, the width of formingzone 35 generally matches the width ofwire 20. As such,wire 20 is bent from itsunformed state 20 a by forming points 36-39 so that its formedstate 20 b is generally similar to the shape of formingzone 35. Forming points 36-39 can be configured in a variety of ways to create a variety of shapes for formingzone 35, and thus for formedstate 20 b ofwire 20. - In one example illustrated in
FIG. 3 a, formingzone 35 has a sinusoidal shape defining an amplitude (Y35) and a wavelength (λ35). Aswire 20 is indexed or moved through formingzone 35 indirection 25, forming points 36-39 are moved toward and away fromwire 20. As such, formedstate 20 b ofwire 20 can be a continuous sinusoidal shape. -
FIG. 3 b illustrates a segment ofwire 20 in a formedstate 20 b that is formed in a formingstation 14 in accordance with one embodiment. In the example,wire 20 is bent from itsunformed state 20 a by forming points 36-39 to generally be similar to the shape of formingzone 35, such thatwire 20 in a formedstate 20 b has an amplitude (Y20) and has a wavelength (λ20). The respective amplitudes (Y35 and Y20) and wavelengths (λ35 and λ20) of formingzone 35 andwire 20 in a formedstate 20 b can be similar, but are not necessarily identical. In one example,wire 20 has some spring-back associated with it such thatwire 20 in a formedstate 20 b has an amplitude (Y20) that is slightly smaller than the amplitude (Y35) of formingzone 35 and has a wavelength (λ20) that is slightly longer than the wavelength (λ35) of formingzone 35. In one example,wire 20 is a metal, such as a cobalt based superalloy. - An illustration of a process of bending
wire 20 from itsunformed state 20 a into its formedstate 20 b is given inFIGS. 4-5 .FIGS. 4-5 illustrate first through fourth forms 31-34 and first through fourth forming points 36-39 independently and sequentially moving toward and away fromwire 20 as it moves frominput 12 to output 16 through formingstation 14, thereby bendingwire 20 into a formedstate 20 b.FIG. 3 b illustrates a portion ofwire 20 into its formedstate 20 b that is formed using the processes illustrated inFIGS. 4-5 . -
FIG. 4 illustrates an initiation of a process starting with awire 20 that is completely in anunformed state 20 a as the process begins. In the example, it is referred to as initial wire processing.FIG. 5 illustrates subsequent processing where at least some bending ofwire 20 has already occurred as the process begins. In the example, it is referred to as subsequent wire processing. -
FIG. 4 a illustrateswire 20 entering first through fourth forms 31-34 in formingstation 14 in anunformed state 20 a, such as frominput 12.Output 16 is referenced to the left in the figure. In one embodiment, this illustrates the initial wire processing for bendingwire 20. InFIG. 4 a,fourth form 34 is illustrated “in” towardwire 20, while first through third forms 31-33 are illustrated “out” away fromwire 20. InFIG. 4 b,first form 31 is illustrated actuated in towardwire 20.Fourth form 34 remains in and second and third forms 32-33 remain out. Asfirst form 31 is actuated in,wire 20 is moved by the impact of first formingpoint 36 againstwire 20. - In
FIG. 4i c,second form 32 is illustrated actuated in towardwire 20. First andfourth forms third form 33 remains out. Assecond form 32 is actuated in,wire 20 is bent from itsunformed state 20 a by the combined impact of first and second formingpoints wire 20. InFIG. 4 d,fourth form 34 is illustrated actuated out away fromwire 20. First andsecond forms third form 33 remains out. - In
FIG. 4 e,third form 33 is illustrated actuated in towardwire 20. First andsecond forms fourth form 34 remains out. Asthird form 33 is actuated in,wire 20 is bent from itsunformed state 20 a by the combined impact of second and third formingpoints wire 20. Becausefourth form 34 remains out at that point in time,wire 20 is allowed to move on the side ofinput 12. As such, only approximately one half of a single wavelength (λ20) ofwire 20 is bent at one time from anunformed state 20 a to a formedstate 20 b. At that point, a single wavelength (λ20) ofwire 20 is constrained between formingpoints - In
FIG. 4 f,first form 31 is illustrated actuated out away fromwire 20. Second andthird forms fourth form 34 remains out. InFIG. 4g ,fourth form 34 is illustrated actuated in towardwire 20. Second andthird forms first form 31 remains out. Asfourth form 34 is actuated in,wire 20 is bent from itsunformed state 20 a by the combined impact of third and fourth formingpoints wire 20. In this way, only approximately one half of a single wavelength (λ20) ofwire 20 is bent at one time from anunformed state 20 a to a formedstate 20 b. At that point, a single wavelength (λ20) ofwire 20 is constrained between formingpoints - In
FIG. 4 h,second form 32 is illustrated actuated out away fromwire 20. Third andfourth forms first form 31 remains out. InFIG. 4 i,third form 33 is also illustrated actuated out away fromwire 20. First andsecond forms fourth form 34 remains in. As such, at the end of the initial wire processing, since each of first, second andthird forms wire 20 is not impinged by them and can be readily moved or indexed for subsequent wire processing. -
FIGS. 5 a-5 i illustrate one embodiment of such subsequent wire processing. As withFIG. 4 i, inFIG. 5 a onlyfourth form 34 is illustrated actuated in towardwire 20, while first, second andthird forms FIG. 4 i,wire 20 inFIG. 5 a is indexed slightly towardoutput 16. For example, viewingFIG. 4 i, a first wavelength (λ20) in wire 20 (i.e., that portion ofwire 20 that transitions from “up” to “down” to “up” again, as viewed inFIG. 4i ) is generally “below” formingpoint 37 ofform 32. InFIG. 5 a,wire 20 is indexed towardoutput 16 by one wavelength (λ20) such that that same wavelength (λ20) is now moved past formingpoint 36 ofform 31 on the side ofoutput 16. - In
FIG. 5 b,first form 31 is illustrated actuated in towardwire 20.Fourth form 34 remains in and second and third forms 32-33 remain out. InFIG. 5c ,second form 32 is illustrated actuated in towardwire 20. First andfourth forms third form 33 remains out. Asfirst form 31 is actuated in, a previously bent portion ofwire 20 is secured by first and second formingpoints wire 20. InFIG. 5 d,fourth form 34 is illustrated actuated out away fromwire 20.Third form 33 remains out and first andsecond forms wire 20. - In
FIG. 5 e,third form 33 is illustrated actuated in towardwire 20. First andsecond forms fourth form 34 remains out. Asthird form 33 is actuated in,wire 20 is bent from itsunformed state 20 a by the combined impact of second and third formingpoints wire 20. Becausefourth form 34 remains out at that point in time,wire 20 is allowed to move on the side ofinput 12. As such, only approximately one half of a single wavelength (λ20) ofwire 20 is bent at one time from anunformed state 20 a to a formedstate 20 b. At that point, a single wavelength (λ20) ofwire 20 is constrained between formingpoints - In
FIG. 5 f,first form 31 is illustrated actuated out away fromwire 20. Second andthird forms fourth form 34 remains out. InFIG. 5 g,fourth form 34 is illustrated actuated in towardwire 20. Second andthird forms first form 31 remains out. Asfourth form 34 is actuated in,wire 20 is bent from itsunformed state 20 a by the combined impact of third and fourth formingpoints wire 20. In this way, only approximately one half of a single wavelength (λ20) ofwire 20 is bent at one time from anunformed state 20 a to a formedstate 20 b. At that point, a single wavelength (λ20) ofwire 20 is constrained between formingpoints - In
FIG. 5 h,second form 32 is illustrated actuated out away fromwire 20. Third andfourth forms first form 31 remains out. InFIG. 5 i,third form 33 is also illustrated actuated out away fromwire 20. First andsecond forms fourth form 34 remains in. As such, at the end of the subsequent wire processing, since each of first, second andthird forms wire 20 is not impinged by them and can be readily moved or indexed for additional subsequent wire processing. - One skilled in the art will understand that the subsequent wire processing illustrated in
FIGS. 5 a-5 i can be repeated onwire 20 in order to create a continuous piece of formed material having a substantially periodic, and in one example, sinusoidal-like shape, over its length. The overall length can be varied in accordance with the desired application.Wire 20 in its formedstate 20 b has sinusoidal shape with an amplitude (Y20), and is generally flat along the z-axis (the dimension coming out of the page as viewed inFIGS. 2 , 3 a and 3 b, for example). - As is evident from the subsequent wire processing illustrated in
FIGS. 5 a-5 i, when first andsecond forms wire 20 in its formed state. This is illustrated, for example, inFIG. 5 e where first andsecond forms wire 20. When third andfourth forms wire 20 in itsunformed state 20 and bend it into its formedstate 20 b. This is illustrated, for example, inFIG. 5 e, wherethird form 33bends wire 20 from itsunformed state 20 to its formedstate 20 b, and inFIG. 5 g, wherefourth form 34bends wire 20 from itsunformed state 20 to its formedstate 20 b. In addition, in this last example ofFIG. 5 g,third form 33 also constrainswire 20 after it has been bent in order forfourth form 34 to accurately bendwire 20. - As is evident from the initial and subsequent wire processing illustrated in
FIGS. 4-5 , approximately one half of a single wavelength (λ20) ofwire 20 is bent at one time from anunformed state 20 a to a formedstate 20 b. Put another way, when forming points 36-39 of forms 31-34 are actuated to bendwire 20 from anunformed state 20 a to a formedstate 20 b, less than a single wavelength (λ20) ofwire 20 is bent at one time. In one embodiment, when the wavelength (λ20) ofwire 20 is significantly less than the amplitude (Y20) ofwire 20, bending an entire wavelength (λ20) or more ofwire 20 from anunformed state 20 a to a formedstate 20 b at one time with forming points 36-39 can cause the formedstate 20 b to be a distorted sinusoidal shape, ofeven cause wire 20 to brake or fracture. - In one embodiment,
wire 20 has a diameter of four thousandths of one inch (0.004 inch). In other embodiments,wire 20 has a diameter as small as one half of one thousandths of one inch (0.0005), and in others it is as large as ten thousandths of one inch (0.010 inch). Also, a single wavelength (λ20) ofwire 20 created by forming points 36-39 is approximately twenty-four thousandths of one inch (0.024 inch), while the amplitude (Y20) ofwire 20 in its formedstate 20 b is and approximately forty thousandths of one inch (0.040 inch). With these fairly small dimensions, and with this ratio of amplitude (Y20) to wavelength (λ20),wire 20 is fairly easily bent, and if a full wavelength (λ20) or more is bent from anunformed state 20 a to a formedstate 20 b at one time, the sinusoidal formedstate 20 b illustrated inFIG. 3 a will not be achieved. - Also, where the amplitude (Y20) of
wire 20 in its formedstate 20 b is significantly larger than a single wavelength (λ20) of formedwire 20, as illustrated inFIG. 3 b, bending a relatively small diameter into a sinusoidal shape cannot effectively be achieved with a gear or tooth-type mechanism, which would effectively bend an entire wavelength (λ20) ofwire 20 over a tooth of the gear. - In one example, a formed
wire 20 b has a sinusoidal shape where a single wavelength (λ20) ofwire 20 is approximately fifty percent (50%) of the amplitude (Y20), while in another example it is approximately sixty percent (60%) and in yet another it is ninety percent (90%). The length of forming points 36-39 (as illustrated inFIG. 3 ) can be readily adjusted to create these various proportions. - In one embodiment, each of forms first through fourth forms 31-34 are configured for independent actuation such that they move independently and consecutively in and out of a forming
zone 35, for example moving along rails 51-54. As such, the distance that forms 31-34 are actuated towardwire 20 can readily be adjusted during the forming process by regulating the distance of travel along rails 51-54. In this way, the amplitude (Y20) of the formedstate 20 b can be adjusted. In one embodiment, the amplitude (Y20) of the formedstate 20 b is adjusted during the forming process such that the overall amplitude (Y20) of the formedstate 20 b ofwire 20 varies over its length. - Similarly, when forms 31-34 and mounting blocks 41-44 are mounted on rails in the x-axis, the wavelength (λ20) of
wire 20 can be adjusted. This is particularly true in the tapered region to accommodate for the slightly different wavelength produced at different amplitudes. -
FIG. 6 illustrates one example of awire 20 in a formedstate 20 b that has been formed with an amplitude (Y20) that varies over its length. For example, near the center of the portion onwire 20 illustrated, the amplitude (Y20max) is at a maximum and toward the ends of the portion the amplitude (Y20min) is at a minimum. One skilled in the art will understand that the amplitude can be adjusted in various ways to achieve a wire in a formedstate 20 b having various tapered forms. - In one embodiment, the indexing or moving a
wire 20 through formingstation 14 along the x-axis is done mechanically by physically movingwire 20 by one wavelength (λ20), as described and illustrated above in the transition fromFIG. 4 i toFIG. 5 a. In another embodiment, this indexing ofwire 20 can be achieved automatically with formingdevice 10. -
FIG. 7 illustrates a portion of formingstation 14 for formingdevice 10 in accordance with one embodiment. Formingstation 14 includes first through fourth forms 31-34,wire guide 28 andindex pin 29.Wire guide 28 includesslot 28 a. In the illustration,wire 20 in anunformed state 20 a enters forms first through fourth forms 31-34 and exits in a formedstate 20 b. - In operation,
wire 20 is bent from itsunformed state 20 a to its formedstate 20 b with first through fourth forms 31-34 in accordance with the process described relative toFIGS. 4 a-4 i and/or 5 a-5 i. In one embodiment, formingstation 14 is configured with awire guide 28, which in one example is configured to directwire 20 in its formedstate 20 b towardguide pin 29. In one example,wire guide 28 is configured withslot 28 a, into whichwire 20 moves in its formedstate 20 b. InFIG. 7 , a portion ofwire 20 that has enteredslot 28 a and isinside guide 28 is illustrated in dotted lines. -
Guide pin 29 is configured to be actuated along the z-axis, or in and out of the page as presented inFIG. 7 . In one example, guide 28 is configured with a cylindrical bore that receivesguide pin 29 so thatguide pin 29 can be actuated up or away fromguide slot 28 a so thatwire 20 in its formedstate 20 b can travel underguide pin 29 withinslot 28 a. Then, guide pin can be actuated down or towardguide slot 28 a so thatwire 20 in its formedstate 20 b can be pinned withinguide slot 28 a byguide pin 29, thereby holdingwire 20 in place. - In one embodiment, guide 28 and
guide pin 29 are moveable along the x-axis relative to first through forms 31-34. As such, guide 28 andguide pin 29 can be used toindex wire 20 relative to first through fourth forms 31-34. In one example, guide 28 andguide pin 29 are in a “back” position towardoutput 16 along the x-axis.Guide pin 29 is initially “up” (along the z-axis) and away fromguide slot 28 a such thatwire 20 can move freely inslot 28 a. Then, guidepin 29 is actuated “down” (along the z-axis) to hold the wire in place. - Next,
wire 20 is formed in accordance with the process described inFIGS. 4 a-4 i and/or 5 a-5 i. Then, with at least two of first through fourth forms 31-34 still in toward wire 20 (along the y-axis), thereby holding it in place,guide pin 29 is actuated “up”. Then, guide 28 andguide pin 29 are moved to a “forward” position towardinput 12 along the x-axis. Then, guidepin 29 moves downward (along the z-axis) to clamp or holdwire 20 withinguide slot 28 a. - Next, all of first through forms 31-34 move out away from wire 20 (along the y-axis).
Guide 28 andguide pin 29 are then moved back towardoutput 16 approximately one wavelength along the x-axis. First and second forms 31-32 then move in toward wire 20 (along the y-axis) and holdwire 20, then third and forth forms 33-34 actuate to bend another portion ofwire 20. This process can then be repeated to continually index andbend wire 20. - In one embodiment, one or more of first through forth forms 31-34 can be movable along the x-axis in addition to along the y-axis. In this way, the forms themselves can be used to
index wire 20. For example, rails similar to rails 51-54 inFIG. 2 could extend along the x-axis and allow first through forth forms 31-34 to be actuated in that direction as well. - In one example, guide 28 is stationary in all x-, y- and z-axis axes, and guide
pin 29 is stationary in the x- and y-axes, while moving in the z-axis.Guide pin 29 starts out in the “down” position.Wire 20 is formed in accordance with the process described inFIGS. 4 a-4 i and/or 5 a-5 i. Then, first andsecond forms Guide pin 29 is then actuated “up” (along the z-axis). - Next, first and
second forms output 16 approximately one wavelength along the x-axis.Guide pin 29 then moves downward (along the z-axis) to clamp or holdwire 20 againstguide 28 withinguide slot 28 a. Next, first andsecond forms second forms input 12 approximately one wavelength along the x-axis (back to the position from which they came). - Then, first and first and second 31 and 32 are transitioned in toward
wire 20 along the y-axis to hold the part. Then, third andfourth forms wire 20 in accordance with the process described inFIGS. 4 a-4 i and/or 5 a-5 i.Guide pin 29 is then retracted fromguide slot 28 a, and this process can then be repeated to continually index andbend wire 20. - One skilled in the art understands that various embodiments are possible to accomplish the indexing of
wire 20. This can be done automatically, or even manually with an operator moving the wire after each sequence detailed inFIGS. 5 a-5 i by one wavelength and visualizing each index one at a time. - One skilled in the art also understands that various periodic shapes may be achieved for the formed
state 20 b ofwire 20.FIG. 8 illustrates a portion of first through fourth forms 71-74 of a formingstation 14 in accordance with one embodiment. InFIG. 8 , each of forms 71-74 and are illustrated as extended fully “in” towardwire 20 such that a space or formingzone 75 is left between the collective group of forms 71-74. - In one example, each of first through fourth forms 71-74 respectively include forming points. In this example, the forming points further include features or grooves that give a forming zone 75 a modified sinusoidal shape. Although
wire 20 bent in formingzone 75 will have a periodic shape, it will not be a true sinusoidal shape. Formingzone 75 has a modified sinusoidal shape defining an amplitude (Y75) and a wavelength (λ75). One skilled in the art will understand that various shape for forming zones are achievable with modification to the forms. For example, the forms can include other features, or may even be slanted slightly to produce “tilted” sinusoidal formed wires. - Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present invention. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof
Claims (21)
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US12/127,582 US20080289389A1 (en) | 2007-05-25 | 2008-05-27 | Wire-forming apparatus |
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US94030507P | 2007-05-25 | 2007-05-25 | |
US12/127,582 US20080289389A1 (en) | 2007-05-25 | 2008-05-27 | Wire-forming apparatus |
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US12/127,582 Abandoned US20080289389A1 (en) | 2007-05-25 | 2008-05-27 | Wire-forming apparatus |
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US9296034B2 (en) | 2011-07-26 | 2016-03-29 | Medtronic Vascular, Inc. | Apparatus and method for forming a wave form for a stent from a wire |
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