Claims:
1. A system for testing a mechanical life of one or more springs, the system comprising:
a pair of plates having an upper fixed fixture plate 3 and a linearly movable lower fixture plate 2, the upper fixed fixture plate 3 coupled with an upper spring fixture 5 and the linearly movable lower fixture plate 2 coupled with a lower spring fixture 1, the one or more springs are connected between the upper fixed spring fixture 3 and the linearly movable lower fixture plate 2 using one or more threaded dowel pins, and wherein the linearly movable lower fixture plate 2 is adapted to move linearly up and down for testing based on a pre-defined stroke pre-set to obtain a resultant spring force associated with the one or more springs.
2. The system as claimed in claim 1, wherein the linearly movable lower fixture plate is adapted to move linearly up and down for testing preferably by using a ball screw and a motor arrangement
3. The system as claimed in claims 1 and 2, wherein during testing, the motor rotates in a pre-defined speed causing the ball screw to translate the rotational motion of the motor into linear motion, thus moving the linearly movable lower fixture plate in an upward and a downward direction according to clockwise and anticlockwise rotation of the motor respectively.
4. The system as claimed in claim 1, wherein the one or more threaded dowel pins comprise of a grove, preferably a U-shaped or V-shaped grove, adapted to securely hold the one or more springs during the testing.
5. The system as claimed in claim 1, wherein the linearly up and down movement of the linearly movable lower fixture plate provide tension or compression forces to the one or more springs.
6. The system as claimed in claim 1, wherein the resultant spring force is continuously obtained by a load cell 15, the load cell measures a linear resultant force of the one or more springs to be recorded by one or more monitoring unit.
7. The system as claimed in claim 6, wherein the load cell is connected between the upper fixed fixture plate and the upper fixed spring fixture.
8. The system as claimed in claim 1, wherein the upper fixed fixture plate and the linearly movable lower fixture plate are connected between at least two guide pillars by using guide supports such that the linearly movable lower fixture plate moves linearly up and down for testing along the length of the guide pillars.

9. The system as claimed in claim 1, wherein the pre-defined stroke are pre-set in the system and are feed based on a CAT number associated with the one or more springs.
10. The system as claimed in claim 1, wherein if a spring selected from the one or more springs is broken during the testing, the system stops based on load differences of the one or more springs.

, Description:TECHNICAL FIELD
[0001] The present disclosure generally relates to the field of testing equipments. In particular, it pertains to, but not by way of limitation, computer aided automated endurance lifecycle testing of spring.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
[0003] A spring is an elastic object used to store mechanical energy. Springs are usually made out of spring steel. There are a large number of spring designs; in everyday usage the term often refers to coil springs. When a spring is compressed or stretched from its resting position, it exerts an opposing force approximately proportional to its change in length (this approximation breaks down for larger deflections). The rate or spring constant of a spring is the change in the force it exerts, divided by the change in deflection of the spring.
[0004] Springs are used in numerous devices and applications. Springs are tested during research and development (and sometimes during manufacturing of end products that include the springs) to ensure that the springs satisfy their design requirements.
[0005] In many cases, it is necessary to measure the load on a spring and to characterize a spring's particular attributes as the spring is acted on by a number of three-dimensional forces. Much of the spring testing equipment already available on the market addresses only Spring under load (“SUL”), and such equipment is not, at least in general, capable of measuring springs in a very low force range due to friction losses. Further, SUL testers are very application specific, while a device with general applicability may be significantly more useful.
[0006] Another deficiency of a number of currently available spring testers is that they fail to describe the effects of (or provide information regarding) all three-dimensional forces acting on a spring. Current equipment, for example, may consider only a side force or a moment in a primary direction, or such equipment may only consider springs tolerating a force range of large magnitude. In general, known testing equipment measures springs with an axial minimum force ranging from about 10 kN to about 20 kN. In other words, known testing equipment only measures springs with high minimum force ranges.
[0007] Manual checking of spring force for defined extension/compression of spring are also well known in the art. Generally, on the basis of spring force spring gets approval. Endurance testing involves testing a spring with a significant load extended (extension and compression) over a significant period of time or number of operation, to discover how the spring behaves under sustained use. The goal is to discover how the spring behaves under sustained use and to calculate number of cycle for springs before failure. That is, to ensure that the throughput and/or response times after some long period of sustained activity are as good as or better than at the beginning of the test.
[0008] The aforementioned limitations of the existing monitoring mechanism of spring life diagnostic are recognized by the inventors hereof and some or all of these limitations have been addressed by various embodiments of the current invention.
[0009] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0010] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0011] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0012] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0013] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.

SUMMARY
[0014] Embodiments of the invention overcome at least some of the drawbacks and deficiencies of prior-art spring tester systems by providing a computer aided automated endurance lifecycle testing of spring.
[0015] An object of the present disclosure is to provide an automated process of endurance testing of mechanical life of springs.
[0016] An aspect of the present disclosure a system for testing a mechanical life of one or more springs. The system includes a pair of plates having an upper fixed fixture plate and a linearly movable lower fixture plate, the upper fixed fixture plate coupled with an upper spring fixture and the linearly movable lower fixture plate coupled with a lower spring fixture. The one or more springs are connected between the upper fixed spring fixture and the lower spring fixture using one or more threaded dowel pins. The linearly movable lower fixture plate is adapted to move linearly up and down for testing based on a pre-defined stroke pre-set to obtain a resultant spring force associated with the one or more springs.
[0017] In an aspect, special purpose machine (SPM) can be used for testing of spring force or endurance test up to 300 kg load.
[0018] In an aspect, the linearly movable lower fixture plate is adapted to move linearly up and down for testing preferably by using a ball screw and a motor arrangement.
[0019] In an aspect, during testing, the motor rotates in a pre-defined speed causing the ball screw to translate the rotational motion of the motor into linear motion, thus moving the linearly movable lower fixture plate in an upward and a downward direction according to clockwise and anticlockwise rotation of the motor respectively.
[0020] In an aspect, the one or more threaded dowel pins comprise of a grove, preferably a U-shaped or V-shaped grove, adapted to securely hold the one or more springs during the testing.
[0021] In an aspect, the linearly up and down movement of the linearly movable lower fixture plate provide tension or compression forces to the one or more springs.
[0022] In an aspect, the resultant spring force is continuously obtained by a load cell, the load cell measures a linear resultant force of the one or more springs to be recorded by one or more monitoring unit.
[0023] In an aspect, the load cell is connected between the upper fixed fixture plate and the upper fixed spring fixture.
[0024] In an aspect, the upper fixed fixture plate and the linearly movable lower fixture plate are connected between at least two guide pillars by using guide supports such that the linearly movable lower fixture plate moves linearly up and down for testing along the length of the guide pillars.
[0025] In an aspect, the pre-defined stroke is pre-set in the system and are feed based on a CAT number associated with the one or more springs.
[0026] In an aspect, if a spring selected from the one or more springs is broken during the testing, the system stops based on load differences of the one or more springs.
[0027] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.
[0029] FIG. 1 illustrates an exemplary proposed 3D Model of spring machine endurance testing (MET), in accordance with an embodiment of the present disclosure.
[0030] FIG. 2A and 2B illustrates an exemplary detail diagram of spring MET, in accordance with an embodiment of the present disclosure.
[0031] FIG. 3 illustrates an exemplary 3D Model of spring fixture assembly, in accordance with an embodiment of the present disclosure.
[0032] FIG. 4 illustrates an exemplary 3D Model of moving assembly, in accordance with an embodiment of the present disclosure.
[0033] FIG. 5 illustrates an exemplary 3D Model of Load cell assembly, in accordance with an embodiment of the present disclosure.
[0034] FIG. 6 illustrates an exemplary flowchart for testing of the springs using a special purpose machine (SPM) in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0035] The following is a detailed description of embodiments of the disclosure illustrated in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0036] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[0037] Embodiments of the invention overcome at least some of the drawbacks and deficiencies of prior-art spring tester systems by providing a computer aided automated endurance lifecycle testing of spring.
[0038] An object of the present disclosure is to provide an automated process of endurance testing of mechanical life of springs.
[0039] An aspect of the present disclosure a system for testing a mechanical life of one or more springs. The system includes a pair of plates having an upper fixed fixture plate and a linearly movable lower fixture plate, the upper fixed fixture plate coupled with an upper spring fixture and the linearly movable lower fixture plate coupled with a lower spring fixture. The one or more springs are connected between the upper fixed spring fixture and the lower spring fixture using one or more threaded dowel pins. The linearly movable lower fixture plate is adapted to move linearly up and down for testing based on a pre-defined stroke pre-set to obtain a resultant spring force associated with the one or more springs.
[0040] In an aspect, special purpose machine (SPM) can be used for testing of spring force or endurance test up to 300 kg load.
[0041] In an aspect, the linearly movable lower fixture plate is adapted to move linearly up and down for testing preferably by using a ball screw and a motor arrangement.
[0042] In an aspect, during testing, the motor rotates in a pre-defined speed causing the ball screw to translate the rotational motion of the motor into linear motion, thus moving the linearly movable lower fixture plate in an upward and a downward direction according to clockwise and anticlockwise rotation of the motor respectively.
[0043] In an aspect, the one or more threaded dowel pins comprise of a grove, preferably a U-shaped or V-shaped grove, adapted to securely hold the one or more springs during the testing.
[0044] In an aspect, the linearly up and down movement of the linearly movable lower fixture plate provide tension or compression forces to the one or more springs.
[0045] In an aspect, the resultant spring force is continuously obtained by a load cell, the load cell measures a linear resultant force of the one or more springs to be recorded by one or more monitoring unit.
[0046] In an aspect, the load cell is connected between the upper fixed fixture plate and the upper fixed spring fixture.
[0047] In an aspect, the upper fixed fixture plate and the linearly movable lower fixture plate are connected between at least two guide pillars by using guide supports such that the linearly movable lower fixture plate moves linearly up and down for testing along the length of the guide pillars.
[0048] In an aspect, the pre-defined stroke is pre-set in the system and are feed based on a CAT number associated with the one or more springs.
[0049] In an aspect, if a spring selected from the one or more springs is broken during the testing, the system stops based on load differences of the one or more springs.
[0050] In an exemplary embodiment, the present invention provides a standard Computer aided automated MET system for multiple springs testing at a time (Tension and compression) up to 300 KG Resultant spring force.
[0051] In an embodiment, the present invention can include an integration of following major components:
Part Number Part name
1 Spring Fixture
2 Lower fixture plate
3 Upper fixture plate
4 C Frame
5 Top fixed plate
6 Linear ball bearing
7 Ball screw nut
8 Ball screw shaft
9 Guide Support
10 Servo motor
11 Servo motor support
12 Coupling
13 Table
14 Thrust bearing
15 Load Cell
[0052] FIG. 1 illustrates an exemplary proposed 3D Model of spring machine endurance testing (MET), in accordance with an embodiment of the present disclosure. FIG. 2A and 2B illustrates an exemplary detail diagram of spring MET, in accordance with an embodiment of the present disclosure.
[0053] As shown in FIGs. 1, 2A, and 2B, the spring testing machine is designed to check spring life cycle. To start the life cycle test, springs are set into spring fixtures which are loaded between upper spring fixture and lower spring fixture with the help of threaded dowel pins. The spring fixture is designed for quick installation and changeover. Spring fixtures are inserted between lower fixture plate and upper fixture plate. After loading of springs into fixtures, command will be given for testing. During testing of springs, lower fixture plate is moving as per defined stroke linearly up and down by ball screw and Servo motor. During this test, a load cell gives the resultant spring force which is continuously recorded into software.
[0054] In an embodiment, a system for testing a mechanical life of one or more springs is disclosed. The system includes a pair of plates having an upper fixed fixture plate 3 and a linearly movable lower fixture plate 2, the upper fixed fixture plate 3 coupled with an upper spring fixture 5 and the linearly movable lower fixture plate 2 coupled with a lower spring fixture 1, the one or more springs are connected between the upper fixed spring fixture 3 and the linearly movable lower fixture plate 2 using one or more threaded dowel pins, and wherein the linearly movable lower fixture plate 2 is adapted to move linearly up and down for testing based on a pre-defined stroke pre-set to obtain a resultant spring force associated with the one or more springs.
[0055] In an embodiment, special purpose machine (SPM) can be used for testing of spring force or endurance test up to 300 kg load.
[0056] In an embodiment, the linearly movable lower fixture plate 2 is adapted to move linearly up and down for testing preferably by using a ball screw 7, 8 and a motor 10 arrangement.
[0057] In an embodiment, during testing, the motor 10 rotates in a pre-defined speed causing the ball screw 7 to translate the rotational motion of the motor into linear motion, thus moving the linearly movable lower fixture plate 2 in an upward and a downward direction according to clockwise and anticlockwise rotation of the motor 10 respectively.
[0058] In an embodiment, the one or more threaded dowel pins 306 comprise of a grove 304, preferably a U-shaped or V-shaped grove, adapted to securely hold the one or more springs 302 during the testing.
[0059] In an embodiment, the linearly up and down movement of the linearly movable lower fixture plate 2 provide tension or compression forces to the one or more springs 302.
[0060] In an embodiment, the resultant spring force is continuously obtained by a load cell, the load cell 15 measures a linear resultant force of the one or more springs 302 to be recorded by one or more monitoring unit.
[0061] In an embodiment, the load cell is connected between the upper fixed fixture plate and the upper fixed spring fixture.
[0062] In an embodiment, the upper fixed fixture plate 3 and the linearly movable lower fixture plate 2 are connected between at least two guide pillars by using guide supports 9 such that the linearly movable lower fixture plate 2 moves linearly up and down for testing along the length of the guide pillars.
[0063] In an embodiment, the pre-defined stroke is pre-set in the system and are feed based on a CAT number associated with the one or more springs.
[0064] In an aspect, if a spring selected from the one or more springs is broken during the testing, the system stops based on load differences of the one or more springs.
[0065] FIG. 3 illustrates an exemplary 3D Model of spring fixture assembly, in accordance with an embodiment of the present disclosure. In an embodiment, as shown in FIG. 3, the spring fixture 310 is used to locate and support the springs 302 from both ends.
[0066] The locating pin 308 as shown in the FIG. 3 can be used to locate the spring fixture 310 in the correct position, and to reduce installation time.
[0067] As shown in FIG. 3 the springs 302 end is passed through a dowel pin 306 and the dowel pin 306 is inserted into the spring fixture 310. The dowel pin 306 is threaded at one end for easy insertion or removal from the fixture 310. The Dowel pin 306 has a V-groove 304 which aids in locating the spring 302 and prevent slippage on the dowel pin 306 during testing.
[0068] FIG. 4 illustrates an exemplary 3D Model of moving assembly, in accordance with an embodiment of the present disclosure. In an embodiment, the moving mechanism is used to give tension or compression force to the springs. It gives a linear up and down motion to the lower fixture plate.
[0069] As shown in FIG. 4, the spring fixture is mounted on lower fixture plate. The lower fixture plate rests on a ball screw unit which is direct coupled with a servo motor shaft. When the test will start, the servo motor will start rotating. The ball screw translates the rotational motion into linear motion, thus moving the lower fixture plate in an upward and downward direction according to clockwise and anticlockwise rotation of servo motor respectively. The ball screw is fixed on both ends with the help of thrust bearings. The servo motor is connected to the base plate. Linear ball bearings are mounted on both ends of the lower fixture plate which are linearly guided by two vertical guide pillars. Both guide pillars are supported using guide supports on both ends.
[0070] FIG. 5 illustrates an exemplary 3D Model of Load cell assembly, in accordance with an embodiment of the present disclosure. In an embodiment, the load cell is critical electrical component of the load cell assembly. It is a device which is used to measure linear resultant force.
[0071] As shown in FIG. 5, the load cell is connected between top fixed plate and upper fixture plate. Linear ball bearings are mounted on the upper fixture plate which is guided using guide pillars. The top fixed plate is fixed at the ends of the guide pillars by using guide supports.
[0072] FIG. 6 illustrates an exemplary flowchart for testing of the springs using a special purpose machine (SPM) in accordance with an embodiment of the present disclosure. In an embodiment, as shown in FIG. 6 the operations of the SPM are initiated by pressing a start button at step 602. Upon initiating, at step 604 if the position of the components is according to the previous settings, a reset button is triggered at step 606.
[0073] At step 608, the operator can select a CAT number of the springs to be tested from HMI of the SPM, and accordingly the springs are inserted to the respective locations at step 610. The operator loads the springs into spring fixture and fasten the spring fixtures. As per CAT number, the mode of operation and the speed of operation will be selected for expansion or compression stroke. So, lower fixture plate will set position as per CAT number.
[0074] Upon insertion of the springs in the SPM, a cycle start button can be pressed at step 612. The operator will operate Start Button. Accordingly, the test will continuously run for defined number of cycles the SPM measures the spring force and number of cycles at step 614.
[0075] In an embodiment, if one of the spring under test getting damage/broken, then machine determines the same based on the load difference at step 616 and will stop based on load differences at step 618.
[0076] The test results for the testing of the springs are generated at step 620. In an embodiment, all the data will be stored into database server.
[0077] Although the preferred embodiments have been described, it should be pointed out that changes are possible and attainable without departing from the scope of the present invention.
[0078] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0079] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

ADVANTAGES OF THE INVENTION
[0080] According to the present invention a single machine can be used to test different type of springs.
[0081] According to the present invention a single machine can be used to test springs of different length.
[0082] The present invention by way of testing can improve quality of products by improving quality of components.
[0083] The present invention enables an error-free production.
[0084] The present invention enables a live update of the settings i.e., there is no need to stop the program and restart.
[0085] The present invention enables the program to be resumed from last operations automatically even power supply is cut off.
[0086] The present invention indirectly saves cost as it may predict which springs are better springs.
[0087] The present invention is an automated tool and hence reduces human error and reduce customer complain.
[0088] The present invention enables compression and tension spring to be tested on same setup.
[0089] The present invention enables number of cycle to be set if required for limited cycle test.
[0090] The present invention enables testing of multiple springs on same time to reduce testing time.