Cold header screw production detection method

Abstract

The invention relates to a cold header screw production detection method, which comprises the following steps of configuring a detection assembly, setting detection related parameters through parameter configuration, and setting a production quantity counting rule and an alarm triggering condition at the same time; when the proximity switch is lightened once and the sensor senses twice, a counting function and a formal detection function are triggered, and the rotating speed of the cold header is synchronously collected and displayed; the detection parameters of each screw are compared with preset parameters through a logic judgment unit, and meanwhile the mold state, the screw material supply condition and the impact force in the production process are monitored; when an alarm triggering condition is met, an alarm signal is immediately sent out, and the cold heading machine is synchronously controlled to stop and stop feeding; if the proximity switch works normally and the sensor is damaged, only the rotating speed display function of the cold heading machine is reserved, and counting and all detection functions are invalid; if the sensor works normally and the proximity switch is damaged, the counting function and all the detection functions fail. According to the method, the reliability, flexibility and management efficiency of screw production detection are improved.

Description

Technical Field

[0001] This invention relates to a screw production inspection method, and more particularly to a cold heading machine screw production inspection method. Background Technology

[0002] Cold heading machines, as core equipment in screw production, achieve rapid processing of screw heads and shanks through a cold extrusion molding process using molds. They offer advantages such as high production efficiency and stable forming accuracy, and are widely used in machinery manufacturing, construction, automotive parts, and other fields. During mass production of screws, the integrity of the mold (punch) directly determines the quality of the screw product. Molds subjected to prolonged cold extrusion impact are prone to cracking and breakage. If these defects are not detected in time, they will continue to be produced, resulting in defective screws with poor head forming and dimensional deviations. This not only leads to a significant waste of metal raw materials but also increases subsequent sorting costs. Furthermore, defective products flowing into downstream processes can cause assembly failures, resulting in economic losses and reputational risks for the manufacturing company.

[0003] To reduce losses caused by mold damage and product defects, most existing cold heading machine production lines are equipped with basic detection devices to monitor abnormalities during screw production. Currently, conventional detection methods primarily rely on a single sensor to sense the screw forming status or a counter to count the production quantity. An alarm is triggered when obviously defective products are detected or a preset quantity is reached.

[0004] However, existing testing technologies have many limitations, making it difficult to meet the needs of high-precision, comprehensive production testing: First, their testing functions are limited; most devices can only detect one type of abnormality (such as quantity meeting standards or material shortage), failing to simultaneously cover multiple common faults such as mold breakage, short screws, and material impact during production. This easily leads to missed detections, resulting in the continuous production of defective products. Second, the adjustability of testing accuracy is poor. The detection parameters for key faults such as mold breakage and material impact are mostly fixed values, making it impossible to adjust the detection sensitivity according to different screw specifications and different production conditions. This makes it difficult to adapt to diverse production needs, either missing minor faults due to insufficient accuracy or generating false alarms due to excessive accuracy, affecting production continuity. Third, there is a lack of a scientific mechanism for establishing testing benchmarks. The devices often rely on preset thresholds for judgment without a startup sampling calibration step, making them prone to inaccurate results due to sensor drift and initial equipment state deviations. Fourth, the counting function is incomplete, mostly using single-channel counting, which cannot simultaneously control the total production quantity and the daily production quantity, hindering production progress statistics and batch management. Fifth, the adaptability of detection components is poor; when core detection components such as proximity switches and sensors are partially damaged, the device often malfunctions or triggers a full-function failure, failing to retain basic auxiliary functions (such as speed display), which is detrimental to troubleshooting and emergency handling. Sixth, each detection function lacks an independent control mechanism, making it impossible to selectively enable or disable specific detection items according to production needs, resulting in poor flexibility and difficulty in adapting to different working conditions such as screw adjustment and batch production. Summary of the Invention

[0005] To address the above problems, this invention provides a method for inspecting the production of cold heading machine screws. The specific technical solution is as follows: A method for inspecting screws produced on a cold heading machine is applied to the screw production process. It is used to detect the mold condition and screw quality, and to trigger alarms and stop the machine and feeding in case of abnormalities. The method includes the following steps: Step 1: Configure the detection component, which includes a proximity switch and a sensor. Set the relevant detection parameters through parameter configuration, and set the production quantity counting rules and alarm triggering conditions. Step 2: During the screw production process, when the proximity switch is lit once and the sensor is sensed twice, the counting function and formal detection function are triggered, and the speed of the cold heading machine is collected and displayed simultaneously. Step 3: The detection parameters of each screw are compared with the preset parameters through the logic judgment unit, while the mold status, screw material supply and impact force during production are monitored. Step 4: When the alarm triggering conditions are met, immediately issue an alarm signal and simultaneously control the cold heading machine to stop and stop feeding. Step 5: If the proximity switch is working normally but the sensor is damaged, only the cold heading machine speed display function will be retained, and the counting and all detection functions will be disabled; if the sensor is working normally but the proximity switch is damaged, the counting function and all detection functions will be disabled.

[0006] Preferably, the counting rule in step 1 is implemented using two counters. The two counters have the same function and are defined as total production quantity count and daily production quantity count, respectively, with corresponding total production target value and daily production target value set. In step 4, when the production quantity reaches the target value set by either counter, an alarm shutdown and material feeding stop operation are triggered.

[0007] Preferably, the detection-related parameters in step 1 include short material detection parameters, which correspond to parameters H-01 and H-02. In step 3, the screw length is detected in real time. When a short screw is detected, it is judged as an anomaly, and the anomaly handling operation in step 4 is executed.

[0008] Preferably, the detection-related parameters mentioned in step 1 include punch breakage detection parameters. The smaller the value of the punch breakage detection parameters, the higher the accuracy of mold damage detection. In step 3, the mold status is monitored by the punch breakage detection parameters. When the mold is determined to be damaged, the abnormal handling operation in step 4 is executed.

[0009] Preferably, the detection-related parameters mentioned in step 1 include material detection parameters. The smaller the value of the material detection parameters, the higher the impact force detection accuracy. In step 3, the impact force during the production process is monitored through the material detection parameters. When the impact force exceeds the preset threshold, the abnormal handling operation in step 4 is executed.

[0010] Preferably, the detection-related parameters in step 1 include the sampling quantity setting parameter H-03, which is used to set the sampling quantity of screw parameters when the machine is powered on; In step 2, when the number of screws produced reaches the sampling quantity, the detector automatically enters the formal testing mode. Subsequently, the testing parameters of each screw are compared with the sampling parameters to complete the screw qualification judgment.

[0011] Preferably, step 1 also includes a sensor position adjustment step: the sensor installation position parameters are displayed in real time through parameter H-04, and the sensor is adjusted to the appropriate position corresponding to parameter H-04 so that the sensor can be adjusted to the appropriate position. After ensuring that the detection function of the detection component is in an effective working state, screw production and detection are started.

[0012] Preferably, step 3 also includes material shortage detection: real-time monitoring of screw material supply; when screw material is detected to be exhausted, it is determined to be abnormal, and the abnormal handling operation in step 4 is executed, issuing an alarm signal and simultaneously controlling the cold heading machine to stop and stop feeding.

[0013] Preferably, each detection function is configured with an independent start / stop control. The corresponding detection function is turned on or off individually by a start / stop switch. The activated detection function participates in the real-time detection in step 3, while the deactivated detection function is not included in the real-time detection range.

[0014] Preferably, the alarm signal in step 4 is an audible and visual alarm, and the alarm record is stored through the control module. The alarm record includes the alarm type, alarm time and corresponding production quantity, which facilitates subsequent fault investigation and production traceability.

[0015] Compared with the prior art, the present invention has the following beneficial effects: This invention provides a screw production inspection method for cold heading machines that integrates full-dimensional fault detection functions such as mold breakage, short material, material impact, and no material. It is equipped with adjustable accuracy parameters, H-03 start-up sampling benchmark, dual-channel counter, and independent function start / stop switch. It designs differentiated detection component fault adaptation logic and alarm-stop-material stop linkage mechanism. Moreover, it relies on simple core detection components to achieve synergistic adaptation of structure and method. It effectively overcomes the defects of existing detection devices, such as single function, fixed accuracy, inaccurate detection, inconvenient management, poor fault adaptation, and incomplete abnormality handling. It simultaneously improves the reliability, flexibility, and management efficiency of screw production inspection, and has the advantages of low cost and easy promotion. It can significantly reduce material waste and production losses and ensure product quality stability. Detailed Implementation

[0016] The present invention will now be further described with reference to the embodiments.

[0017] A method for inspecting screws produced on a cold heading machine is applied to the screw production process. This method detects the mold condition and screw quality, triggering alarms and stopping the machine and feeding to reduce material waste and production losses. The method includes the following steps: Step 1: Configure the detection component, which includes a proximity switch and a sensor. Set the relevant detection parameters through parameter configuration, and set the production quantity counting rules and alarm triggering conditions. Step 2: During the screw production process, when the proximity switch is lit once and the sensor is sensed twice, the counting function and formal detection function are triggered, and the speed of the cold heading machine is collected and displayed simultaneously. Step 3: The detection parameters of each screw are compared with the preset parameters through the logic judgment unit, while the mold status, screw material supply and impact force during production are monitored. Step 4: When the alarm triggering conditions are met, immediately issue an alarm signal and simultaneously control the cold heading machine to stop and stop feeding. Step 5: If the proximity switch is working normally but the sensor is damaged, only the cold heading machine speed display function will be retained, and the counting and all detection functions will be disabled; if the sensor is working normally but the proximity switch is damaged, the counting function and all detection functions will be disabled.

[0018] The counting rule in step 1 is implemented using two counters. The two counters have the same function and are defined as total production quantity count and daily production quantity count, respectively. The total production target value and daily production target value are set accordingly. In step 4, when the production quantity reaches the target value set by either counter, an alarm shutdown and material feeding operation are triggered.

[0019] The detection-related parameters mentioned in step 1 include the short material detection parameters, which correspond to parameters H-01 and H-02. In step 3, the screw length is detected in real time. When a short screw is detected, it is judged as an anomaly, and the anomaly handling operation in step 4 is executed.

[0020] The detection parameters mentioned in step 1 include punch breakage detection parameters. The smaller the value of the punch breakage detection parameters, the higher the accuracy of mold damage detection. In step 3, the mold status is monitored by the punch breakage detection parameters. When the mold is determined to be damaged, the abnormal handling operation in step 4 is executed.

[0021] The detection-related parameters mentioned in step 1 include material detection parameters. The smaller the value of the material detection parameters, the higher the impact force detection accuracy. In step 3, the impact force during the production process is monitored through the material detection parameters. When the impact force exceeds the preset threshold, the abnormal handling operation in step 4 is executed.

[0022] The detection-related parameters mentioned in step 1 include the sampling quantity setting parameter H-03, which is used to set the sampling quantity of screw parameters when the machine is powered on; In step 2, when the number of screws produced reaches the sampling quantity, the detector automatically enters the formal testing mode. Subsequently, the testing parameters of each screw are compared with the sampling parameters to complete the screw qualification judgment.

[0023] Step 1 also includes a sensor position adjustment step: the sensor installation position parameters are displayed in real time through parameter H-04. The sensor is adjusted to the appropriate position corresponding to parameter H-04 so that the sensor can be adjusted to the appropriate position. After ensuring that the detection function of the detection component is in an effective working state, screw production and detection are started.

[0024] Step 3 also includes material shortage detection: real-time monitoring of screw material supply. When screw material is detected to be exhausted, it is determined to be abnormal, and the abnormal handling operation in step 4 is executed, issuing an alarm signal and simultaneously controlling the cold heading machine to stop and stop feeding.

[0025] Each detection function is configured with independent start / stop control. The corresponding detection function can be turned on or off individually by using a start / stop switch. The activated detection function participates in the real-time detection in step 3, while the deactivated detection function is not included in the real-time detection range.

[0026] The alarm signal mentioned in step 4 is an audible and visual alarm. At the same time, the alarm record is stored through the control module. The alarm record includes the alarm type, alarm time and corresponding production quantity, which facilitates subsequent fault investigation and production traceability.

[0027] Used in cold heading machines to produce screws, this instrument detects the screws during the manufacturing process. Because the screw head has a forming mold, it prevents the mold from breaking and producing defective screws. When the mold is damaged and a defective screw is produced, the detector will alarm and stop the machine, thus preventing waste of screw materials and reducing production losses.

[0028] Two counters are used to set the production target quantity. When a fixed value is set, an alarm will sound and the machine will stop when the production reaches the set value. The two counters have the same function but can be assigned different definitions, such as the total set value and the set value for the day.

[0029] It has a short-material function. When the screws are adjusted to a fixed length for production, if a screw is short during production, the detector will alarm and stop the machine. The corresponding short-material parameters on the instrument are H-01 and H-02.

[0030] There are punch breakage parameters. When the die is damaged during screw production, the detector instrument will alarm and stop the machine. The smaller the punch breakage parameter setting, the higher the accuracy.

[0031] It has a feeding function. When there is a large impact during the screw production process, it will alarm and stop the machine. The smaller this parameter is, the higher the precision.

[0032] One parameter, H-03, is the setting for the number of screw parameters sampled when the machine is powered on. When the sampling number is reached, the machine enters the detection mode, and the parameters of each subsequent screw are compared with the sampled parameters to determine whether the screw is good or bad.

[0033] The H-04 parameter is used to display the adjustment of the sensor position. When the sensor is adjusted to a suitable position, the detection function is effective.

[0034] There is a material shortage function; when the screw material is exhausted, the detector will sound an alarm.

[0035] There is also a stop feeding function when all alarms are triggered.

[0036] The instrument has two main external detection components: a proximity switch and a sensor. During the screw production process, the proximity switch illuminates once, and the sensor detects twice, generating a count and indicating that the detection function is valid, with the speed displayed.

[0037] If the proximity switch is working properly but the sensor is faulty, it will only display the rotational speed. If the sensor is working properly but the proximity switch is faulty, it will not display any detection functions.

[0038] Each detection function has a small switch that can turn the corresponding detection function on or off.

[0039] This invention integrates multiple functions such as mold fracture detection, short material detection, material impact detection, and no material detection. Compared with existing single-function detection devices, it can simultaneously monitor the core fault types in the screw production process, achieving comprehensive control from mold status, product size, production impact force to material supply. This avoids the continuous production of unqualified screws due to missed detection, significantly reduces raw material waste and subsequent sorting and rework costs, and ensures product quality stability.

[0040] For mold breakage and material impact detection, high-precision adjustable parameters are set. The smaller the parameter value, the higher the detection accuracy. The detection sensitivity can be adjusted according to the production process of different screw specifications and the operating conditions of different cold heading machines. This avoids missing minor mold damage due to insufficient accuracy, and also prevents false alarms due to excessive accuracy, thus balancing detection reliability and production continuity.

[0041] By setting parameters for the H-03 sampling quantity, the preset number of screws are sampled first after power-on. The sampled parameters are used as the benchmark for subsequent testing, effectively offsetting the detection errors caused by sensor drift and initial equipment state deviation. Compared with the existing method of judging directly based on fixed thresholds, this method greatly improves the accuracy of screw qualification judgment and reduces production interruptions or defective products due to misjudgment.

[0042] The system employs two independent counters, which can separately control the total production quantity and the daily production quantity, facilitating production progress statistics, batch management, and capacity planning, thus overcoming the limitations of the existing single counter function. At the same time, each detection function is equipped with an independent start / stop switch, which can selectively activate the required detection items according to different working conditions such as screw adjustment and batch production, thereby improving the equipment's operational flexibility and adaptability.

[0043] Differentiated adaptation logic is designed for fault detection components. When the proximity switch is normal but the sensor is damaged, the speed display function is retained, which makes it easy for operators to quickly locate the fault type. When an abnormality occurs, alarm, shutdown and material feeding stop linkage control are realized to avoid secondary waste caused by the continued feeding of remaining materials after shutdown and equipment jamming. At the same time, the audible and visual alarms and alarm record storage help to quickly troubleshoot the fault and shorten downtime.

[0044] The detection component uses only two core external components: a proximity switch and a sensor. It has a simple structure, controllable cost, and is suitable for the retrofitting and new installation of various existing cold heading machines. The corresponding detection method has clear steps and progressive logic, and can be put into production without complicated operation training. It can quickly help manufacturing enterprises reduce economic losses caused by mold damage and product defects, improve the intelligence and precision of screw production, and has broad industry application value.

Claims

1. A method for inspecting screws produced on a cold heading machine, applied in the screw production process of a cold heading machine, used to detect the mold condition and screw quality, and to realize abnormal alarms, machine shutdown, and feeding cessation, characterized in that... Includes the following steps: Step 1: Configure the detection component, which includes a proximity switch and a sensor. Set the relevant detection parameters through parameter configuration, and set the production quantity counting rules and alarm triggering conditions. Step 2: During the screw production process, when the proximity switch is lit once and the sensor is sensed twice, the counting function and formal detection function are triggered, and the speed of the cold heading machine is collected and displayed simultaneously. Step 3: The detection parameters of each screw are compared with the preset parameters through the logic judgment unit, while the mold status, screw material supply and impact force during production are monitored. Step 4: When the alarm triggering conditions are met, immediately issue an alarm signal and simultaneously control the cold heading machine to stop and stop feeding. Step 5: If the proximity switch is working normally but the sensor is damaged, only the cold heading machine speed display function will be retained, and the counting and all detection functions will be disabled; if the sensor is working normally but the proximity switch is damaged, the counting function and all detection functions will be disabled.

2. The method for inspecting cold heading machine screws according to claim 1, characterized in that, The counting rule in step 1 is implemented using two counters. The two counters have the same function and are defined as total production quantity count and daily production quantity count, respectively. The total production target value and daily production target value are set accordingly. In step 4, when the production quantity reaches the target value set by either counter, an alarm shutdown and material feeding operation are triggered.

3. The method for inspecting cold heading machine screws according to claim 1, characterized in that, The detection-related parameters mentioned in step 1 include the short material detection parameters, which correspond to parameters H-01 and H-02. In step 3, the screw length is detected in real time. When a short screw is detected, it is judged as an anomaly, and the anomaly handling operation in step 4 is executed.

4. The method for inspecting cold heading machine screws according to claim 1, characterized in that, The detection parameters mentioned in step 1 include punch breakage detection parameters. The smaller the value of the punch breakage detection parameters, the higher the accuracy of mold damage detection. In step 3, the mold status is monitored by the punch breakage detection parameters. When the mold is determined to be damaged, the abnormal handling operation in step 4 is executed.

5. The method for inspecting cold heading machine screws according to claim 1, characterized in that, The detection-related parameters mentioned in step 1 include material detection parameters. The smaller the value of the material detection parameters, the higher the impact force detection accuracy. In step 3, the impact force during the production process is monitored through the material detection parameters. When the impact force exceeds the preset threshold, the abnormal handling operation in step 4 is executed.

6. The method for inspecting cold heading machine screws according to claim 1, characterized in that, The detection-related parameters mentioned in step 1 include the sampling quantity setting parameter H-03, which is used to set the sampling quantity of screw parameters when the machine is powered on; In step 2, when the number of screws produced reaches the sampling quantity, the detector automatically enters the formal testing mode. Subsequently, the testing parameters of each screw are compared with the sampling parameters to complete the screw qualification judgment.

7. The method for inspecting cold heading machine screws according to claim 1, characterized in that, Step 1 also includes a sensor position adjustment step: the sensor installation position parameters are displayed in real time through parameter H-04 so that the sensor can be adjusted to the corresponding appropriate position. After ensuring that the detection function of the detection component is in an effective working state, screw production and detection are started.

8. The method for inspecting cold heading machine screws according to claim 1, characterized in that, Step 3 also includes material shortage detection: real-time monitoring of screw material supply. When screw material is detected to be exhausted, it is determined to be abnormal, and the abnormal handling operation in step 4 is executed, issuing an alarm signal and simultaneously controlling the cold heading machine to stop and stop feeding.

9. A method for inspecting cold heading machine screws according to claim 1, characterized in that, Each detection function is configured with an independent start / stop control. The corresponding detection function can be turned on or off individually by using a start / stop switch. The activated detection function participates in the real-time detection in step 3, while the deactivated detection function is not included in the real-time detection range.

10. A method for inspecting cold heading machine screws according to claim 1, characterized in that, The alarm signal mentioned in step 4 is an audible and visual alarm. At the same time, the alarm record is stored through the control module. The alarm record includes the alarm type, alarm time and corresponding production quantity, which facilitates subsequent fault investigation and production traceability.