Flat Die Rolling Correction Using Test-Piece Streak Deviation
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Solution Overview
Problem
The relative positions of a fixed flat die and a moving flat die in a rolling apparatus need precise alignment to ensure high-quality thread formation, but conventional methods rely heavily on operator skill and require multiple iterations for accurate adjustment.
Innovation Solution
A rolling apparatus with top-dead-center position adjusting means, test-movement control, positional-deviation-amount inputting, correction-movement-amount calculation, and opposing-position adjusting means to automatically and visually guide the alignment of the fixed and moving flat dies, using streaks formed in a test piece to calculate and adjust the relative positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manual adjustment methods are used for aligning the fixed flat die and moving flat die, then the alignment precision can be achieved through operator skill, but the adjustment process requires multiple iterations and heavily depends on operator experience
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated control system that uses sensors to detect the positions of the fixed flat die and moving flat die, and automatically adjusts them to achieve precise alignment. This substitution eliminates dependence on operator skill and reduces iterative adjustments.
Solution Approach 2:
The patent implements a feedback mechanism where sensors continuously monitor the positions of the flat dies, and the control system uses this information to automatically adjust the alignment. This closed-loop feedback ensures precise alignment without requiring multiple manual iterations.
2Manufacturing precision
If multiple test iterations are performed for alignment correction, then the alignment precision can be improved, but the production time and efficiency are reduced
Solution Approach 1:
The patent performs preliminary alignment detection and adjustment before actual thread production begins. The control system uses sensors to detect positions and automatically corrects alignment issues in advance, eliminating the need for multiple test iterations during production and thereby maintaining high efficiency.
3Ease of operation
If automated control systems are implemented for die alignment, then the ease of operation and productivity are improved, but the device complexity increases
Solution Approach 1:
The control system is designed to automatically perform alignment detection and adjustment without requiring complex manual intervention. The system uses sensors to detect positions and automatically calculates and executes the necessary adjustments, making the operation simple while managing complexity through automation.
Data Source
AI summary
The rolling apparatus is configured to execute a control content for producing a test piece by forming fixed-side streaks and moving-side streaks in a base material, and a control content for receiving an inputted positional deviation amount between groove center lines of the moving-side streaks and virtual groove center lines of the fixed-side streaks, and then for calculating and outputting a correction movement amount, based on the positional deviation amount, for use in correcting and adjusting the moving flat die at a top dead center thereof. Further, the rolling apparatus is configured to execute a control content for receiving and outputting an input of bite depths of the fixed-side streaks and moving-side streaks in the test piece.