Shaping Roller Arrangement for Thread Profile Processing
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Solution Overview
Problem
Existing devices for non-cutting processing of elongated workpieces to produce thread-like profiles require multiple shaping rollers with different profiles and sizes, leading to increased wear and a substantial inventory of rollers, making them inefficient and costly to operate.
Innovation Solution
The device employs at least two axially consecutive shaping roller arrangements with identical rollers, each with three shaping rollers, where the axial position of each roller is adjustable within a fixed installation dimension, and the rollers of one arrangement are offset by a full circle relative to the adjacent arrangement, allowing for varied workpiece diameters and profiles to be processed with a single set of rollers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple shaping rollers with different profiles are used to process workpieces of different diameters and profiles, then the device can handle a variety of workpiece types, but the number of required rollers increases substantially, leading to increased wear and higher operational costs
Solution Approach 1:
The patent implements a universal shaping roller system where a single roller with a specific profile geometry can process workpieces of various diameters and profiles. The roller head assembly is designed to accommodate different workpiece types through adjustable positioning mechanisms and universal profile geometries that adapt to multiple processing requirements, eliminating the need for multiple specialized rollers.
Solution Approach 2:
The patent utilizes parameter changes by modifying the axial position and angular orientation of the shaping roller within the roller head assembly. By adjusting these parameters, the same roller can effectively process workpieces with different diameters and profile requirements, reducing the inventory needed while maintaining versatility.
2Adaptability or versatility
If multiple shaping rollers with different profiles are maintained in inventory to handle various workpiece types, then adaptability is improved, but the wear and tear on rollers increases due to frequent replacement and usage of multiple rollers
Solution Approach 1:
The universal roller design ensures that a single roller can be used extensively across different workpiece types without premature wear. The roller profile geometry and material selection are optimized for general-purpose processing, distributing wear more evenly and extending service life compared to specialized rollers used infrequently.
Solution Approach 2:
The patent enables continuous processing of different workpiece types using the same roller through quick-change positioning mechanisms. This eliminates downtime for roller replacement and maintains consistent processing quality, improving reliability while reducing the frequency of roller changes and associated wear.
3Device complexity
If the axial position of shaping rollers is fixed, then the device structure is simpler, but the ability to process workpieces with different diameters and profiles is limited
Solution Approach 1:
The patent implements dynamic roller positioning within the roller head assembly, allowing the shaping roller to be adjusted axially and angularly during operation. This dynamic adjustment capability enables the same roller to accommodate different workpiece diameters and profiles without requiring complex reconfiguration, balancing simplicity with adaptability.
Solution Approach 2:
The patent adds adjustment dimensions to the roller positioning system, allowing movement not only axially but also in angular orientation. This multi-dimensional adjustment capability provides versatility for processing various workpiece types while maintaining a relatively simple overall device structure through standardized adjustment mechanisms.
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 design enables efficient and precise processing of workpieces with different diameters and profiles, reduces the number of required rollers, and allows for uniform machining and heat treatment, increasing the service life of the workpieces and reducing material waste.
Implementation Method 1
forming rollers rotatable about axes, the forming roller arrangement surrounding the workpiece to be machined, with an infeed movement between the forming rollers and the workpiece in its circumferential direction as well as axially to this, and wherein the forming rollers during a complete revolution around the workpiece successively come into a forming engagement with this
Data Source
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AI summary
The invention relates to a device for processing elongate workpieces without cutting in order to produce a thread-like outer profile by means of at least one shaping roller arrangement (9, 10, 11) having shaping rollers (12, 13, 14), which can be rotated about respective axes (12', 13', 14'), wherein the shaping roller arrangement (9, 10, 11) surrounds the workpiece to be processed, wherein a feed motion between the shaping rollers (12, 13, 14) and the workpiece is established in the circumferential direction of the workpiece and axially to the workpiece, and wherein the shaping rollers (12, 13, 14) are brought into a shaping engagement with the workpiece in succession during a complete revolution around the workpiece, wherein at least two axially successive shaping roller arrangements (9, 10, 11) are provided in the passing direction (8) of the workpiece, wherein at least the shaping rollers (12, 13, 14) of a shaping roller arrangement (9, 10, 11) are the same as each other and, in order to provide shaping engagements with the workpiece that are successive in the direction of the revolution around the workpiece, the axial position of each shaping roller (12, 13, 14) within an axial installation dimension (28) is different. The invention further relates to a method for processing elongate workpieces without cutting by means of such a device.