Random shape spring - more than 100 turns

[ren1911]

Hi everyone, I need to design random shape (combination of circle and line) of spring with closely packed turns (way more than 100). So far I could only design a shape with turns that look like a telephone cord using the Sweep Boss/Base feature. But it is limited to a max of 100 turns. I need about thousands, if not more. Any suggestion on how it can be achieved? I am a newbie and would greatly appreciate your help. Thanks ahead!

[shift1313]

im not sure i understand the circle/line combo. do you have any pictures? also you can do an array of the component. If it repeats itself make a few turns and create a bunch of copies using the linear array.

[ren1911]

Hi, here's the pic of what I could do so far. I need a similar shape with more than 100 turns. Thank you for suggesting the linear array, I haven't used it before, will give it a try. Just wondering though, I need the coils to be connected from the beginning to the end, with no wall or division in between the arrays. Any suggestion will be a great help. Thanks a lot.

[Glen Smith]

I don't know anything about Solid Works, but could you do the 2 straight sections and 4 quadrants of the circle as 6 separate parts then union them together?

 

Glen

[shift1313]

ren, so you need that exact thing just with more turns right?

[shift1313]

okay i drew this real quick but i think its sorta what you are looking for.

 

First thing i did was draw the key hole shape on a sketch(that will be used as a path later)

 

second i created a plane at the end of one of the straight sections so i could draw a circle(location for a circle).

 

Next i used this circle that is perpendicular to the path to make a helix. The important part here is that I set my pitch of the helix to whatever you need and i make my start angle 0degrees and 1 full rotation. This gives me 1 coil.

 

Next i create a small circle on the top plane that will be swept along this 1 turn helix to make 1 ring.

 

Last but not least I use the Linear Pattern drop down, you will see a curve driven pattern. As long as the first keyhole sketch has all tangent sections(sharp corners have a fillet applied to them) you will be able to use it as your path. You will select the swept "ring" for your object(feature) and your parth you will need to right click, select other and make sure you select your entire sketch and not just one segment of it. I will have to play with the fillet in your sketch. If its too sharp your coils will not joint properly.

 

 

I think it will take a little bit of playing with but if i were to model it thats the first method i would try. You can also play with the pattern function and patern your sketch(i think).

 

There might be a way to create your helix along the path but ive never tried that before so i couldnt tell you if it works or not.

 

ps, i used 1000coils here.

[shift1313]

one more thing you may want to look into. you can make a straight coil maybe and bend it to your shape. There is a flexible tubing options for the routing wizard.

 

what do you need to do with the model? is this for production or does it just have to look right?

[ren1911]

Hi Matt,

 

Thanks a lot for your awesome suggestions! Regarding the first method, it seems good, but I need total continuity, cannot have any detached planes like you showed in the zoomed pic. I'll have to see if fillet options can solve that.

 

This option sounds very promising "you can make a straight coil maybe and bend it to your shape. There is a flexible tubing options for the routing wizard." Haven't used a flexible tubing option before and don't know where to find it, but I'll give it a try and will let you know what happens.

 

This is to model an electrical inductor I'm working on using a simulating software with limited CAD for my school project, not for production, but I need the continuity to simulate current flow. Thanks again for the suggestions, will keep you posted.

[shift1313]

your welcome. I played with it a few different ways and i still cant find a method to make the helix on the path. Obviously it can be done in a few parts and you can mate these together. Doing it in one operations so to speak would be easier.

 

out of curiousity. how are you going to simulate the current flow with the model?