Reciprocating Die Roll Forming Machine Reducing Cycle Time
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Solution Overview
Problem
Current thread rolling machines are complex, cumbersome, and require experienced operators, with high maintenance and repair costs due to the use of heavy metal components and synchronization challenges with reciprocating dies, limiting their long-term commercial success.
Innovation Solution
A reciprocating die roll forming machine with symmetrical, flat tooling that uses servo-motors, belt drives, and light-weight slides on recirculating bearings, allowing both dies to move simultaneously to form patterns on cylindrical blanks without the need for a starter finger, reducing cycle time and eliminating the complexity of die timing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heavy metal components and traditional reciprocating die mechanisms are used, then the machine can perform thread rolling, but the device complexity and maintenance costs increase significantly
Solution Approach 1:
The patent removes the traditional insertion finger mechanism and starter finger components from the thread rolling machine. By extracting these complex elements, the invention simplifies the overall device structure while maintaining the essential thread rolling capability through a more straightforward die arrangement.
Solution Approach 2:
Instead of using a stationary die with a reciprocating moving die that requires an insertion finger to position the blank, the patent inverts the approach by using two reciprocating dies that move toward each other. This inversion eliminates the need for complex insertion mechanisms and starter fingers, reducing device complexity.
2Reliability
If traditional reciprocating die machines with insertion fingers are used, then thread forming can be achieved, but the ease of operation decreases due to synchronization requirements
Solution Approach 1:
The patent employs two identically driven reciprocating dies that automatically synchronize their movement through the drive mechanism. The system self-regulates the timing and positioning of both dies, eliminating the need for operators to manually coordinate complex synchronization, thereby improving ease of operation.
3Strength
If heavy metal components are used in thread rolling machines, then structural strength is sufficient, but the loss of time increases due to maintenance and repair requirements
Solution Approach 1:
The patent eliminates heavy, wear-prone metal components such as insertion fingers and starter fingers that require frequent maintenance and replacement. By discarding these problematic elements in favor of a simplified die design, the machine reduces maintenance time and operational downtime while maintaining sufficient structural strength for thread rolling.
4Reliability
If traditional thread rolling machines with complex mechanisms are used, then thread formation can be achieved, but the productivity decreases due to longer cycle times
Solution Approach 1:
The patent implements a continuous reciprocating motion system where both dies move simultaneously toward each other, eliminating idle time associated with sequential operations and insertion mechanisms. This continuous action approach reduces the production cycle time while maintaining reliable thread formation, thereby improving productivity.
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 significantly reduces cycle time, minimizes maintenance needs, and lowers operational costs by enabling efficient production of threaded fasteners with improved alignment and reduced operator skill requirements, while maintaining high precision and durability.
Implementation Method 1
Cold forming of a thread, gear tooth or other pattern upon a cylindrical blank utilizing reciprocating, symmetrical dies represents known technology
Implementation Method 2
axial translation of the dies from the fully retracted position to the fully inserted position causing the blank to rotate about its longitudinal center between the pattern forming faces
Data Source
AI summary
A reciprocating die roll forming machine for forming a pattern such as a thread form on the outer surface of a cylindrical blank includes at least one set of reciprocating dies operating upon the blank which rotates in place. The machine includes a slide and bearing combination to support the dies belt driven by a servo-motor controlled by a central processing unit. Mechanism is provided to deliver and position a blank for engagement by the dies. In one form, the machine includes multiple die sets to produce multiple parts during one die reciprocation cycle. In another form, the machine employs separate drive mechanisms to independently drive each die of a set.