Implementación de un prototipo de máquina automática dobladora de alambre para fabricación de resortes

Abstract

This degree project aims at the implementation of a prototype automatic wire bending machine for the manufacturing of helical compression springs, focused on improving the precision and efficiency of the production process compared to manual methods used in small industrial workshops. Currently, springs are fundamental components in multiple industrial sectors such as automotive, agricultural, medical, and general industry, due to their ability to store mechanical energy, absorb impacts, and maintain constant forces within dynamic systems. However, despite the high demand and the technical requirements in parameters such as length, pitch, and number of coils, a large portion of their production in small-scale environments continues to be carried out manually, which limits uniformity, increases production time, and makes compliance with quality standards more difficult. As a response to this problem, the design and construction of an automated prototype capable of manufacturing compression springs from 22-gauge steel wire is proposed, allowing the user to configure parameters such as length and pitch through a Human–Machine Interface (HMI). The system integrates mechanical, electrical, and control components, combining two NEMA 17 stepper motors for the wire feeding and forming system, a servomotor for the cold cutting mechanism, a power supply, and a control system based on Arduino with A4988 drivers and a Nextion touchscreen display. The project development included structural mechanical design modeled in SolidWorks, stress analysis using the Von Mises criterion, evaluation of displacements and unit strains, as well as power calculations, bending forces, cutting forces, and the dimensioning of shafts, gears, and transmission elements. Fundamental theoretical principles of helical compression springs were also considered, including Hooke’s Law, geometric design parameters, lateral buckling stability, and material selection according to ASTM standards.