Roller Burnishing Tool With Wedge Adjustment for Tooth Gap Accuracy
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Solution Overview
Problem
Conventional roller burnishing tools face challenges in maintaining accurate tooth gap dimensions due to variations in steel quality, requiring time-consuming and costly adjustments, including replacing rollers, which is inefficient and costly.
Innovation Solution
The burnishing tool incorporates a wedge-shaped intermediate body with adjustable spacers and a hydrostatic pressure chamber, allowing for precise adjustment of roller position and penetration depth without replacing rollers, and uses electrical resistance heating to control contact pressure, enabling quick adaptation to dimensional deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rollers are replaced to adjust penetration depth for dimensional deviations, then manufacturing precision can be maintained, but loss of time and productivity decrease due to time-consuming replacement processes
Solution Approach 1:
The roller support is made dynamically adjustable through a wedge-shaped intermediate body that can be moved axially to change roller penetration depth. This dynamic adjustment mechanism allows the roller to adapt to different dimensional requirements without physical replacement, resolving the contradiction between maintaining precision and avoiding time loss.
Solution Approach 2:
The penetration depth parameter of the roller is made variable through the wedge-shaped intermediate body adjustment mechanism. By changing the axial position of the intermediate body, the roller penetration depth can be continuously adjusted to compensate for dimensional deviations in the workpiece, eliminating the need for roller replacement while maintaining manufacturing precision.
2Manufacturing precision
If rollers are replaced to adapt to different dimensional requirements, then manufacturing precision is maintained, but device complexity increases due to roller inventory and replacement mechanisms
Solution Approach 1:
The wedge-shaped intermediate body serves multiple functions: it supports the roller, enables axial adjustment of penetration depth, and acts as a positioning element. This multi-functional component eliminates the need for multiple specialized rollers, reducing inventory complexity while maintaining the ability to achieve different dimensional requirements through adjustment.
Solution Approach 2:
The adjustable intermediate body creates a dynamic system where a single roller can adapt to different dimensional requirements through position adjustment rather than replacement. This reduces the complexity of managing roller inventory while maintaining manufacturing precision across different production scenarios.
3Device complexity
If conventional roller burnishing tools are used without adjustment mechanisms, then device complexity is low, but manufacturing precision deteriorates due to inability to compensate for steel quality variations
Solution Approach 1:
The wedge-shaped intermediate body introduces a simple yet effective dynamic adjustment capability to the burnishing tool. By allowing axial movement of the intermediate body, the system gains the ability to compensate for steel quality variations and maintain manufacturing precision without excessive complexity.
Solution Approach 2:
The roller penetration depth parameter is made variable through the adjustable intermediate body, enabling the system to adapt to different material conditions. This parameter change capability resolves the contradiction by providing the necessary adjustment functionality with minimal added complexity.
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 solution allows for rapid and cost-effective adjustments to maintain accurate tooth gap dimensions, reducing the need for extensive roller replacement and minimizing installation space requirements, while extending tool service life.
Implementation Method 1
an intermediate body (11) is provided, in particular a wedge-shaped intermediate body (11), which exerts pressure on the bearing journals (2) of the rollers (1)
Implementation Method 2
an intermediate body is provided which includes a hydrostatic pressure chamber. By changing the hydrostatic pressure, the position of the rollers relative to the blank can be changed
Implementation Method 3
the temperature of the intermediate body or another element that exerts the contact pressure can be controlled, preferably by means of electrical resistance heating
Data Source
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AI summary
The invention relates to a roller burnishing tool for generating a tooth structure in a wall (6.2) of a cylindrical blank (6), comprising the following features: • - a clamping device for holding the blank (6); • - an annulus of disc-shaped rotatably mounted rollers (1), the peripheral edges of which are directed against the wall (6.2) of the blank and are pressed against the same; • - bearing journal (2) for mounting the rollers (1); • - a stamp (9) in the inner cavity of the blank (6) having a tooth structure as a counter-mould; • - a drive for generating a relative movement in a feed direction (7) between the rollers (1) and the blank (6). The invention is characterized by the following features: • - a wedge-shaped intermediate body (11) is provided which presses the rollers (1) on the bearing journal (2) by exerting a pressure, stabilizes said intermediate body in a fixed environment, and the position of said intermediate body in the feed direction (7) is determined by at least one replaceable spacer.