Rotary Forging Load Measurement for Accurate Dynamic Calibration
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Solution Overview
Problem
In rotary forging devices, the inability to accurately measure the actual load applied to an object while the pressing die is swung and rotated leads to difficulties in calibrating the set load value, resulting in imprecise processing and unreliable pre-pressure application in hub unit bearings.
Innovation Solution
The implementation of a dynamic load measurement method using a measuring pressing die and a measuring shaft member, supported by a load cell, allows for accurate measurement of the actual load applied in the direction of the reference axis, even when the pressing die is swung and rotated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a pressing die is swung and rotated during forging, then the caulking part can be formed with desired shape, but the actual load applied to the object becomes difficult to measure accurately
Solution Approach 1:
A reaction force measurement mechanism is introduced as an intermediary to indirectly measure the actual load applied to the object. The mechanism includes a reaction force application portion that receives the reaction force from the object, a transmission portion that transmits this force, and a measurement portion that converts the transmitted force into a measurable signal. This intermediary system enables accurate load measurement during the dynamic swinging and rotating forging process without interfering with the shaping operation.
2Manufacturing precision
If the set load value is not accurately calibrated, then the processing precision deteriorates, but calibration becomes impossible without dynamic load measurement capability
Solution Approach 1:
The measurement portion provides real-time feedback on the actual load applied to the object during forging. This feedback is used to calibrate the set load value by comparing it with the measured actual load. The calibration process adjusts the set load value based on the difference between the set value and the measured value, ensuring that future operations use accurate load parameters for precise processing.
3Measurement precision
If a load cell is used to measure load, then load measurement becomes possible, but offset load from swinging motion causes measurement error
Solution Approach 1:
The measurement of offset load caused by swinging motion is separated from the measurement of axial load. The reaction force measurement mechanism is specifically designed to measure only the axial component of the load applied to the object, excluding the offset load components. This is achieved by positioning the reaction force application portion to receive forces only in the axial direction, thereby extracting the useful measurement signal from the complex multi-directional forces present during swinging rotation.
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 approach enables precise calibration of the set load value, ensuring high-accuracy processing and reliable application of appropriate pre-pressure in hub unit bearings, thereby improving the overall precision and reliability of the rotary forging process.
Implementation Method 1
measuring an actual load in a direction of a reference axis applied to the measuring shaft member
Data Source
AI summary
A measuring pressing die (43) is supported by a spherical concave seat (12). A measuring shaft member (45) is disposed coaxially with a reference axis (α) and is linearly guided in a direction of the reference axis (α) between the measuring pressing die (43) and a support table (16). After that, the load application apparatus measures an actual load in the direction of the reference axis (α) applied to the measuring shaft member (45) using a load cell (48) in a state in which the measuring pressing die (43) is pressed against the measuring shaft member (45) while the measuring pressing die (43) is rotated about the reference axis (α).