Servomotor Flat Die Thread Rolling for Long and Complex Workpieces

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Solution Overview

Problem

Existing flat die thread rolling machines struggle to efficiently process components with large lengths or complex geometries, such as rods, wire sections, or tube material, due to limitations in machining flexibility and stability.

Innovation Solution

The implementation of a servomotor-controlled drive system in the flat die thread rolling machine, allowing for oscillatory motion of the second tool part, enables flexible and precise control over the machining process, including adjustable distances between tool parts and programmable motion profiles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If a traditional crank drive is used to achieve high output through oscillatory motion of the rolling die, then productivity is improved, but the machine cannot process components with large length or complex bending geometries

Engineering Contradiction:

ImproveoutputVSAvoidprocessing capability for long or complex components

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent replaces the fixed mechanical crank drive with a dynamic, programmable oscillating drive system. The drive unit can be controlled through programming to adjust oscillation amplitude, frequency, and motion profile, enabling the machine to adapt to different workpiece lengths and geometries while maintaining high productivity through automated control.

Inventive Principle:

Principle #15Dynamics

2Productivity

If the machine is designed for high output with fixed tool arrangement, then productivity is improved, but flexibility in machining different workpiece types is reduced

Engineering Contradiction:

ImproveoutputVSAvoidmachining flexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent implements programmable control over oscillation parameters (amplitude, frequency, phase) and tool positioning, allowing the machine to optimize processing parameters for different workpiece types and geometries. This enables high productivity through automated processing while maintaining flexibility to machine various component types including long rods, wire sections, and tube material.

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If a servomotor with closed-loop control is implemented to enable precise motion control, then manufacturing precision and flexibility are improved, but device complexity increases

Engineering Contradiction:

Improvethread rolling precisionVSAvoidcontrol system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical coupling and synchronization mechanisms with a programmable control system that uses sensors and feedback loops to coordinate the oscillating drive and tool positioning. This electronic control approach achieves precise thread rolling and synchronized multi-tool operation while reducing mechanical complexity through software-based coordination.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS20250319511A1Flat die thread rolling machine and method for operating such a machine

Publication Date: 2025.10.16 E W MENN GMBH & CO KG MASCHINENFABRIK

AI summary

A flat die thread rolling machine (1) includes a stationarily arranged first tool part (2) and a second tool part (3) that moves relative thereto in an oscillatory manner. The two tool parts (2, 3) have a profiled surface which 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 motion of the second tool part (3). The drive (5) includes a servomotor (6) that is controlled by a machine controller (7).