Modular Thread Rolling Head for Maintenance Efficiency
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Solution Overview
Problem
Existing thread rolling heads are complex systems that require extensive disassembly for maintenance and component replacement, leading to high economic and time-related costs due to wear and adaptability issues for different operating requirements.
Innovation Solution
A modular thread rolling head design where the bearing unit is composed of interchangeable modules with fastening means, allowing for easy assembly and disassembly without full disassembly of the system, enabling adaptation to different operating conditions without requiring detailed knowledge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a complex system structure is used to cover large machining area with small dimensions, then the machining capability is improved, but the device complexity increases and maintenance becomes difficult
Solution Approach 1:
The bearing unit is divided into multiple interchangeable modules, each comprising a housing section and an associated profile roller. This segmentation allows the complex system to be broken down into manageable units that can be independently maintained and replaced, reducing the overall complexity burden while maintaining the large machining area capability.
2Adaptability or versatility
If the thread rolling head is designed as a complex system with many individual parts, then the machining functionality is improved, but the ease of repair deteriorates due to extensive disassembly requirements
Solution Approach 1:
The system is segmented into modular units where each module contains a housing section and profile roller assembly. This allows individual modules to be replaced without disassembling the entire system, significantly improving ease of repair while maintaining comprehensive machining functionality.
Solution Approach 2:
The modular design creates universal interfaces between modules, allowing different profile rollers and housing sections to be interchangeably combined. This universality enables maintenance personnel to replace worn components with equivalent modules without requiring detailed knowledge of the entire system architecture.
3Strength
If traditional assembly methods are used with multiple fastening components, then the structural integrity is improved, but the productivity decreases due to time-consuming assembly and disassembly
Solution Approach 1:
Each module integrates the housing section and profile roller as a unified assembly unit. This merging reduces the number of separate fastening operations required, as modules can be installed as complete units rather than assembling individual components, thereby improving productivity while maintaining structural integrity through the integrated design.
4Reliability
If profile rollers are held on eccentric shafts with multiple fastening elements, then the reliability of the connection is improved, but the ease of operation deteriorates due to complex adjustment requirements
Solution Approach 1:
The profile roller and housing section are segmented into a pre-assembled module that maintains reliable connections internally through optimized fastening. This segmentation moves the complexity of reliable fastening into the module itself, while the external interface becomes simple for operational adjustment and replacement.
Data Source
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AI summary
The invention relates to a thread rolling head comprising a bearing unit (14) in which at least two profile rollers, preferably at least three profile rollers, are rotatably mounted, and a shaft section (10, 16) coupled to the bearing unit (14), wherein the profile rollers define an insertion section between them into which a workpiece to be machined can be inserted, wherein the bearing unit (14) is composed of at least two modules (36, 20) each forming a functional assembly, wherein the modules each have fastening means by which they can be connected to each other and are interchangeable with other modules also each forming a functional assembly, and wherein one of the modules has fastening means for connection with corresponding fastening means of the shaft section.