Fully Automated Production of Circularly Welded Springs

System Design and Functions

Automatic Wire Feeding and Forming:
The spring wire is fed from a coil into a bending machine, wound around a mandrel, and automatically cut. Already during the bending process, the blank takes on a defined preliminary shape, which facilitates subsequent precise forming into the finished Trifeder.

Mandrel and Handling Changeover:
The mandrels are changed automatically via a swiveling double-gripper system. A linear handling system with a swiveling/rotating gripper transports the spring-loaded mandrel to the transfer station.

Position Detection and Transfer of the Spring:
The rotational position of the spring is detected using a vision system. The spring is then transferred to a triangular mounting mandrel via a customized transmission system. The axial position of the spring ends is verified using a camera-based system.

Joining and Welding:
Two robots grip the spring ends, bring them together in a controlled manner, and position them for laser welding. The connection is formed by nearly simultaneous weld spots, which create a dimensionally stable three-spring assembly. Product-specific grippers can be changed as needed.

Quality Assurance:
An indirect inspection is integrated as standard to verify whether the spring retains its shape after being released. Optionally, the weld spots can be visually inspected using a camera.

Another option enables 100% monitoring of weld seams and weld spots directly during the laser process, including analysis of molten pool formation.

Storage and Logistics:
The finished Trifedern are automatically placed into small load carriers (KLT). A downstream roller conveyor system transports the KLTs into the customer’s logistics system. Optionally, an interlayer handling system ensures clean separation of the layers and minimizes the risk of the springs becoming entangled.

System Design and Operation:
The entire machine is constructed as a closed, compact unit mounted on a steel frame and equipped with a safety guard. It is operated via a central touch panel with intuitive user guidance.

The system enables highly automated, repeatable, and scalable production of trifeders, combining precise wire forming, robot-assisted handling, laser welding technology, and modular quality inspection into a single integrated system.