Rebar Thread-Rolling Machine with Pre-Compression Groove
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Solution Overview
Problem
The existing process of preparing reinforcing bars for coupling is inefficient, requiring separate machines for cold rolling, turning, and thread rolling, which is time-consuming and space-intensive, and can damage thread-rolling dies due to contact with protruding ribs.
Innovation Solution
A turning and thread-rolling machine with a pre-compression device that forms a pre-compressed annular groove on the rebar, allowing for integrated cold rolling, turning, and thread rolling in a single apparatus, protecting the thread-rolling dies and improving processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate machines are used for cold rolling, turning, and thread rolling, then each operation can be performed with dedicated equipment, but the processing time increases and factory space requirements increase
Solution Approach 1:
The patent combines cold rolling, turning, and thread rolling operations into a single integrated machine. The machine includes a cold rolling device with rollers, a turning device with cutting tools, and a thread rolling device with thread rolling dies, all mounted on the same machine base and capable of sequential operation on the rebar without removal or transfer between machines.
Solution Approach 2:
The integrated machine performs multiple functions through different devices that can be selectively activated. The machine includes a cold rolling device for surface smoothing, a turning device for end shaping, and a thread rolling device for thread formation, allowing one machine to replace three separate specialized machines while maintaining operation quality.
2Reliability
If separate machines are used for cold rolling, turning, and thread rolling, then each operation can be performed with dedicated equipment, but the factory space occupied increases
Solution Approach 1:
The patent combines cold rolling, turning, and thread rolling operations into a single integrated machine. The machine includes a cold rolling device with rollers, a turning device with cutting tools, and a thread rolling device with thread rolling dies, all mounted on the same machine base and capable of sequential operation on the rebar without removal or transfer between machines.
Solution Approach 2:
The integrated machine performs multiple functions through different devices that can be selectively activated. The machine includes a cold rolling device for surface smoothing, a turning device for end shaping, and a thread rolling device for thread formation, allowing one machine to replace three separate specialized machines while maintaining operation quality.
3Productivity
If thread rolling is performed on unprocessed rebar with ribs, then the processing can proceed without pre-compression, but the thread rolling dies will be damaged by contact with protruding ribs
Solution Approach 1:
The patent applies pre-compression through the cold rolling device before the thread rolling operation. The cold rolling rollers compress the rebar surface and protruding ribs, creating a smoother surface that prevents damage to the subsequent thread rolling dies. This preliminary action eliminates the need for separate pre-processing while protecting the thread rolling dies.
Solution Approach 2:
The cold rolling device performs a preliminary compression action that counteracts the harmful effect of protruding ribs on the rebar. By applying compressive force before thread rolling, the ribs are flattened and the surface is smoothed, preventing the ribs from damaging the thread rolling dies during the subsequent operation.
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
The machine effectively integrates multiple operations, increases the strength of the processed rebar, and prevents damage to thread-rolling dies by forming a pre-compressed annular groove, enabling efficient processing and enhanced structural strength of the coupling end.
Implementation Method 1
the cold-rolling heads and the carrier to compress the unprocessed rebar and thereby form a pre-compressed annular groove
Data Source
AI summary
A turning and thread-rolling machine with a pre-compression device includes a fixing base on which the pre-compression device, a fixing mechanism, a guiding base, a processing mechanism assembly, and a control unit are provided, wherein the pre-compression device includes a carrier and at least two cold-rolling heads in order to form by compression a pre-compressed annular groove in a portion of an unprocessed rebar that is adjacent to one end thereof, and, under the control of the control unit, the fixing mechanism clamps the rebar, and the guiding base displaces the processing mechanism assembly to the end of the rebar to perform turning and thread rolling sequentially, thereby processing the end of the rebar into a coupling end. The pre-compressed annular groove facilitates on-site inspection of thread quality and prevents the thread-rolling dies in the processing mechanism assembly from contact with, and hence damage by, the ribs on the rebar.