Rolling Machine Roller Phasing via Automated Sensor Detection
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Solution Overview
Problem
Current rolling machines lack an efficient method to precisely phase forming rollers, leading to time-consuming, operator-dependent, and costly processes for achieving accurate thread positioning on cylindrical bodies, resulting in inconsistent quality and frequent errors.
Innovation Solution
A rolling machine equipped with sensor means and a logic control unit that automatically detects and adjusts the axial position of forming rollers, allowing for precise and rapid phasing of the rollers, reducing reliance on manual adjustments and test pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual phasing methods are used with test pieces and operator judgment, then the process can be completed with simple equipment, but the time consumption increases significantly and measurement precision deteriorates
Solution Approach 1:
The patent replaces manual mechanical phasing methods with an automated optical sensing system. Sensors detect the axial position of roller threads electronically, eliminating the need for manual measurement with test pieces and operator judgment, thereby achieving both high precision and reduced time consumption
Solution Approach 2:
The system enables self-phasing of the rolling machine through automated detection and control. The sensors automatically detect thread positions and the control unit adjusts roller phases without human intervention, making the machine self-configuring and eliminating dependency on operator skill
2Reliability
If multiple forming rollers are used to distribute stresses, then the reliability of thread formation improves, but the device complexity and phasing difficulty increase
Solution Approach 1:
The patent implements a feedback control system where sensors continuously monitor the axial positions of multiple roller threads and provide data to the control unit. The control unit processes this information and makes real-time adjustments to maintain precise phasing, enabling reliable multi-roller operation without excessive complexity
Solution Approach 2:
The control unit serves multiple functions: it coordinates all forming rollers, processes sensor data from multiple positions, performs calculations for phase adjustment, and controls actuators. This multi-functionality manages the complexity of operating multiple rollers through a single intelligent controller
3Productivity
If traditional phasing processes are used without automated detection, then the equipment cost remains low, but the productivity and consistency of thread formation deteriorate
Solution Approach 1:
The system performs preliminary detection of roller thread positions using sensors before actual thread formation begins. This preliminary action allows the control unit to pre-calculate and establish correct phasing, enabling rapid setup and maintenance operations without compromising productivity
Solution Approach 2:
The patent introduces sensors as intermediary detection devices between the mechanical rollers and the control system. These sensors convert physical thread positions into electrical signals that the control unit can process, bridging the gap between mechanical operation and digital control while maintaining productivity
Data Source
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AI summary
Rolling machine for forming a thread on cylindrical bodies, which comprises two or more forming rollers (6), mechanically associated with the support structure (2) and adapted to plastically deform a cylindrical body arranged along a central work axis (A) of the machine (1). Each forming roller (6) is provided with a thread (8), is driven to rotate around its rotation axis (Z) by a brushless motor (16) and is driven to be moved along a respective first transverse axis (R) perpendicular to the work axis (A) by a corresponding hydraulic piston (15). Sensor means (30) are provided that are mechanically mounted on the support structure (2) and drivable to be moved by movement means (35) between a non-operative position (P1), in which they are in distal position with respect to the forming rollers (6), and an operative position (P2), in which they are in proximity to at least one forming roller (6) in order to detect the axial position of its thread. The invention also relates to a process for phasing the forming rollers of such a rolling machine.