Forming Roller Presetting for Accurate Thread Phasing
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Solution Overview
Problem
Manual phasing of forming rollers in rolling machines for creating external threads on cylindrical bodies is time-consuming, requires significant operator skill, and often results in errors, especially when frequent replacements are needed for different processing types and maintenance, disrupting the production cycle.
Innovation Solution
An independent device that measures the axial coordinate and angular position of forming rollers' threads with respect to a reference plane, using a laser measuring instrument and software to calculate and communicate the necessary phasing data to the rolling machine's numerical control, allowing for precise and repeatable setup without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual phasing operations are used to position forming rollers, then the operator can directly adjust the rollers using intervention on suitable adjustment devices, but the operation requires considerable operator skill and is time-consuming with possible omissions
Solution Approach 1:
The patent replaces manual mechanical adjustment operations with an automated optical measurement system. A laser sensor automatically detects the axial coordinate of the thread on the forming roller, and a control unit calculates and displays the angular position, eliminating the need for manual phasing operations and reducing both time and skill requirements
Solution Approach 2:
The system enables self-service phasing by automatically measuring and calculating the roller positions without operator intervention. The laser sensor and control unit work autonomously to determine the angular position, allowing operators to simply read the displayed values and make adjustments based on objective data rather than manual trial-and-error
2Adaptability or versatility
If frequent replacement of rollers is performed for different processing types and maintenance, then the machine can handle various production requirements, but the phasing process must be repeated frequently disrupting the production cycle
Solution Approach 1:
The patent implements preliminary measurement and calculation of the roller angular position before actual machining begins. By using the laser sensor to detect the axial coordinate and the control unit to calculate the angular position in advance, the system prepares all necessary phasing data beforehand, so when rollers are replaced for different processing types, the new rollers can be quickly phased using the pre-calculated reference values without disrupting the production cycle
3Extent of automation
If sensor means are integrated into the rolling machine to detect axial coordinate, then the machine can automatically determine angular position and phase rollers, but the machine requires built-in measurement sensors which increases complexity
Solution Approach 1:
The patent segments the measurement function from the machining function by using an independent laser sensor system that can be positioned separately from the rolling machine. The laser sensor is mounted on a movable support that can be positioned independently, allowing the measurement system to be added or removed without modifying the core rolling machine structure, thus increasing automation while minimizing added complexity
Solution Approach 2:
The patent introduces an intermediary measurement system consisting of a laser sensor and movable support that bridges the gap between the workpiece and the measurement apparatus. This intermediary setup allows automated detection of the axial coordinate without requiring integrated sensors within the rolling machine itself, enabling automation while keeping the machine structure relatively simple
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate and efficient phasing of forming rollers, reducing operator error and production downtime, and allowing for consistent machine settings even without built-in thread measurement sensors, thereby improving the efficiency and reliability of the rolling process.
Implementation Method 1
uncovering and measuring the axial coordinate of the thread of the forming roller with respect to a predetermined reference plane, with determination of the angular position of the plane containing the characteristic points of at least one thread of the forming roller
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
An independent device for presetting (1) forming rollers for rolling machines for making external threads on cylindrical bodies or pieces to be formed (C) of mechanical parts, is predisposed to determine the characteristic points of the external thread (12) of the forming rollers (10) and detect the angular position or characteristic angle (ϕ) of the beginning of the thread with respect to a predetermined reference plane before the work phase of the machine which receives the data detected for the purpose of the correct phasing of the forming rollers (10) on the same.