Laser Centering of Rotary Caulking Heads for Coaxial Alignment

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Solution Overview

Problem

The rotary caulking device faces issues with poor coaxiality between the concave spherical seat and the rotation body, leading to uneven processing accuracy and preload distribution in the caulking portion, due to inadequate centering methods.

Innovation Solution

A centering method using a laser head and light receiving unit to adjust the position of the rotation body and work holder relative to the frame, ensuring coaxial alignment through iterative adjustments until a predetermined trajectory shape is achieved, thereby improving the coaxiality and machining accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional assembly methods are used for the concave spherical seat and rotation body, then the device complexity is reduced, but the manufacturing precision of coaxiality deteriorates

Engineering Contradiction:

Improvecoaxiality between concave spherical seat and rotation bodyVSAvoidcentering device structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical centering mechanisms with a laser-based optical measurement system. The laser head projects reference rays that are detected by light receiving units to establish coaxiality, eliminating the need for elaborate mechanical alignment devices while achieving high precision positioning between the concave spherical seat and rotation body

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a laser head as an intermediary device that projects reference rays to establish the reference axis. This intermediary optical system mediates the alignment between the concave spherical seat and rotation body, providing a precise and repeatable centering method without requiring direct mechanical contact or complex adjustment mechanisms

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If the coaxiality between concave spherical seat and rotation body is poor, then the device complexity is reduced, but the machining precision of caulking portion deteriorates

Engineering Contradiction:

Improveprocessing accuracy of caulking portionVSAvoidpreload distribution uniformity

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent implements a feedback-based centering method where light receiving units detect the position of reference rays projected by the laser head. The detected positions are used to calculate deviation from the reference axis, and this feedback information guides adjustment operations to achieve precise coaxiality, ensuring both machining precision and reliable preload distribution

Inventive Principle:

Principle #23Feedback

3Measurement precision

If manual centering adjustment is used, then the device complexity is reduced, but the measurement precision of alignment deteriorates

Engineering Contradiction:

Improvealignment measurement accuracyVSAvoidcentering device

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces manual visual or tactile alignment methods with an automated optical measurement system. The laser head projects precise reference rays, and light receiving units automatically detect their positions, converting manual alignment into an automated optical measurement process that achieves higher precision without requiring complex mechanical adjustment devices

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This method enhances the coaxiality between the concave spherical seat and the rotation body, resulting in improved machining accuracy and even preload distribution in the caulking portion, ensuring consistent and precise caulking operations.

Implementation Method 1

a laser head emitting a laser beam onto the center axis of the rotating shaft is attached to the convex spherical seat

Methodology Applied

Scientific EffectLaser: Laser

Data Source

PatentUS11253903B2Centering method of rotary caulking device, rotary caulking device manufacturing method, hub unit bearing manufacturing method, vehicle manufacturing method, centering device of rotary caulking device, and rotary caulking system

Publication Date: 2022.02.22 NSK LTD

AI summary

In a preparation step, a frame (10), a concave spherical seat (15), a convex spherical seat (13), a rotation body (16), a rotating shaft (12), and a work holder (17) are assembled, a laser head (33) is attached to the convex spherical seat (13), and a light receiving unit (38) is attached to the work holder (17). In a rotation body centering step, an irradiation position of a laser beam (LB) with respect to a laser irradiation surface (41) is changed by rotating the rotation body (16) while allowing the laser irradiation surface (41) to be irradiated with the laser beam (LB) emitted from the laser head (33) and a trajectory of the irradiation position is checked.