Hydraulic Piston Tool Positioning for Profile Rolling
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Solution Overview
Problem
Profile rolling machines, such as screwthread rolling machines, face challenges with high clamping pressure that prevents easy release of blanks, often requiring significant force or disassembly, leading to time-consuming and potentially damaging processes.
Innovation Solution
An apparatus with a position-variable piston and adjusting spindle, utilizing a pressure or vacuum connection, allows for easy opening and repositioning of tools without complex adjustments, incorporating a controller for precise force adjustment based on material and dimensions, and featuring additional guidance elements for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high clamping pressure is applied between tools and blank, then profile rolling is achieved, but blank cannot be released and tool opening becomes difficult
Solution Approach 1:
The patent replaces the traditional mechanical lever system with a hydraulic system. A hydraulic cylinder with piston applies opening force to the tool, substituting mechanical leverage with fluid pressure transmission. This allows the tool to be opened even when high clamping pressure is present, as the hydraulic system can generate sufficient opening force without requiring complex mechanical advantage mechanisms.
Solution Approach 2:
The patent employs a hydraulic cylinder-piston mechanism to provide the opening force for the tool. The hydraulic system uses incompressible fluid to transmit force, enabling controlled and powerful opening motion that overcomes the high clamping pressure between the tools and blank, thereby facilitating easy tool release without disassembly.
2Ease of operation
If high leverage force is applied to release blank, then blank can be released, but tool or components may be damaged
Solution Approach 1:
The patent replaces high-leverage mechanical force application with a controlled hydraulic system. The hydraulic cylinder provides gradual and controlled opening force, preventing sudden mechanical impacts that could damage the tool or components. The fluid pressure transmission allows force application that is sufficient to overcome clamping pressure but distributed in a controlled manner.
Solution Approach 2:
The hydraulic system inherently provides cushioning effect through the compressibility characteristics of the hydraulic fluid and the controlled displacement of the piston. This prevents sudden force application and potential damage to the tool or components during the blank release process, as the opening force builds up and releases in a controlled manner rather than through abrupt mechanical leverage.
3Ease of operation
If tools are disassembled for blank release, then blank can be removed, but reassembly and adjustment time is increased
Solution Approach 1:
The patent replaces the disassembly-reassembly process with a hydraulic actuation system. The tool remains assembled, and the hydraulic cylinder simply moves the tool between closed and open positions. This eliminates the time-consuming disassembly and reassembly operations while still allowing complete blank removal, thereby significantly reducing tool repositioning time.
Solution Approach 2:
The patent introduces dynamic positioning capability through the hydraulic cylinder, allowing the tool to move between fixed positions (open and closed) without disassembly. The adjustable piston position enables the tool to be held at different locations along its travel path, providing flexibility in blank removal and tool repositioning while maintaining the tool's assembled state.
4Ease of operation
If adjusting spindle is made position-variable, then tool repositioning is simplified, but device complexity increases
Solution Approach 1:
The patent combines the adjusting spindle with the hydraulic piston assembly, merging two functions (position adjustment and hydraulic actuation) into a single integrated component. The adjusting spindle is positioned within the piston structure, allowing it to be actuated by the hydraulic system while maintaining its adjustment capability. This integration reduces the number of separate components and simplifies the overall device structure.
Solution Approach 2:
The adjusting spindle serves multiple functions: it provides tool positioning, acts as a structural element of the hydraulic assembly, and enables tool adjustment during operation. By making the adjusting spindle position-variable and integrating it with the hydraulic piston, the system achieves multi-functionality that reduces overall device complexity while improving ease of tool repositioning.
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 fast and safe tool opening and repositioning, reducing setup times and preventing damage, while improving cost-effectiveness and safety by allowing flexible and accurate force adjustments.
Implementation Method 1
introducing a pressure medium with a first pressure into the cylinder chamber between the base and a back piston face directed away from the first tool
Implementation Method 2
introducing a vacuum into the chamber between a piston front face directed toward the tool and the base
Data Source
AI summary
The invention relates to an apparatus (100) for positioning a tool (21) in a profile rolling machine, comprising a base (10) and at least one spindle (30) extending in a first bore (17) of the base as abutment for the tool (21). A retraction rod (25) serves as connection between the base and the tool (21). A tractive force for the retraction rod (25) is generated by an actuator (50) and the tool is pulled by the retraction rod (25) against a tool stop (23). The first bore (17) is locally expanded to form a cylinder chamber (12). A piston (40) is mounted in an axially displaceable manner in the chamber (12). A pressure medium (M) is introduced via a pressure connection (46) into the base (10) into the cylinder chamber (12) between the base and the piston (40) for applying a force (F1) on the piston (40).