Servo-Driven Flat-Die Thread Rolling for Complex Workpiece Geometries
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Solution Overview
Problem
Existing flat-die thread rolling machines struggle to efficiently process components with large lengths or complex bending geometries, such as rods, wire sections, or tube material, due to limitations in flexibility and stability, particularly when applying threads or profiles.
Innovation Solution
The implementation of a servo motor controlled by a machine control system to drive the oscillatory movement of the movable tool part, allowing for adjustable distances and customizable speed profiles, enabling flexible and precise thread or profile application on workpieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a crank drive with connecting rod is used to drive the movable rolling die, then the machine achieves high unit output and functional sequences are mapped via cam disks, but components with large component length or complex bending geometries cannot be processed or can only be processed to a very limited extent
Solution Approach 1:
The patent replaces the traditional mechanical crank drive system with a servo motor controlled by a machine control system. The servo motor is controlled via a control unit with a predetermined path or speed profile over the movement cycle, allowing programmable control of the movable rolling die's oscillation. This substitution enables flexible adaptation to different workpiece geometries while maintaining high productivity, as the control system can be programmed with different motion profiles for various component types.
2Device complexity
If the distance between two thread rolling modules is fixed, then the machine structure is simplified, but the machine cannot accommodate different raw material lengths or perform sequential machining steps at different locations
Solution Approach 1:
The patent makes the distance between thread rolling modules adjustable rather than fixed. The modules can be positioned at different distances from each other along the workpiece, allowing the machine to accommodate various raw material lengths and perform sequential machining operations at different locations. This dynamic adjustment capability is controlled by the servo motors and control system, which can coordinate the modules' positions and movements flexibly.
3Reliability
If a traditional crank drive is used, then the machine achieves stable operation, but complex mechanical couplings are required for multi-location machining which increases device complexity
Solution Approach 1:
The patent replaces complex mechanical coupling systems with an electronic control system. Multiple servo motors are coordinated through a control unit that manages their operation independently or in synchronization. This electronic coordination eliminates the need for complex mechanical linkages while maintaining operational stability, as the control system can precisely regulate each module's movement and timing.
Solution Approach 2:
The control unit serves multiple functions: it controls the servo motors for oscillation, manages the positioning of movable tool parts, coordinates multiple thread rolling modules, and adapts motion profiles for different workpiece types. This universal control system replaces multiple specialized mechanical components, reducing overall device complexity while maintaining reliability.
Data Source
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AI summary
The invention relates to a flat-die thread rolling machine (1) comprising a stationary first tool part (2) and a second tool part (3) that is movable in an oscillatory manner relative to the first tool part. The two tool parts (2, 3) have a profile that can be rolled into a workpiece (4) arranged between the tool parts (2, 3). The second tool part (3) is connected to a drive (5) that can cause the oscillatory movement of the second tool part (3). In order to provide such a flat-die thread rolling machine that makes it possible to provide workpieces with a profile, and in particular with a thread, in a more flexible manner, the invention provides that the drive (5) comprises a servomotor (6) that is controlled by a machine control system (7). Furthermore, the invention relates to a method for operating such a flat-die thread rolling machine.