Thread Rolling Die Positioning With Key Bars and Disc Angulation
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Solution Overview
Problem
Current die positioning systems in threaded fastener manufacturing require extensive training and are prone to misalignment due to rapid reciprocating movements and cantilevered positioning, leading to waste and inefficiency.
Innovation Solution
A die positioning system utilizing multiple pairs of key bars, key disc inserts, and disc backers with adjustable thickness and angulation, along with a bearing assembly to stabilize the die holder, ensuring accurate and reproducible positioning of dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If threaded adjustment mechanisms are used to position die faces, then positioning accuracy can be achieved, but operator training time increases and positioning stability decreases
Solution Approach 1:
The patent replaces the traditional threaded mechanical adjustment system with a modular positioning system using precision-machined positioning blocks and interchangeable die holders. This substitution eliminates the need for operators to develop tactile sensitivity through years of training, as the modular components provide repeatable, precise positioning through their geometric features rather than requiring skilled manual adjustment.
Solution Approach 2:
The die positioning system is segmented into separate, interchangeable components including positioning blocks, die holders, and mounting fixtures. Each component can be independently manufactured with precise geometric features that ensure accurate positioning when assembled, eliminating the need for complex threaded adjustments and reducing operator training requirements.
2Manufacturing precision
If threaded adjustment mechanisms are used to position die faces, then positioning accuracy can be achieved, but positioning stability decreases due to accidental shifts
Solution Approach 1:
The positioning system uses segmented, modular components with precise geometric mating features. The positioning blocks have standardized surfaces and mounting features that ensure consistent, stable positioning when assembled with die holders, preventing accidental shifts that occur with threaded adjustments.
Solution Approach 2:
The positioning blocks are pre-machined with precise geometric features during manufacturing. This preliminary action ensures that when the components are assembled, the positioning accuracy is immediately achieved without requiring adjustment, and the rigid geometric connections prevent subsequent accidental shifts during operation.
3Productivity
If rapid reciprocating movement is used for thread rolling, then productivity increases, but positioning accuracy deteriorates due to forces moving the die holder out of alignment
Solution Approach 1:
The patent employs spherical or curved bearing surfaces in the die holder mounting system. These curved surfaces allow the die holder to self-align and absorb dynamic forces generated during rapid reciprocating motion, maintaining positioning accuracy despite the high-speed operation and associated inertial and vibrational forces.
Solution Approach 2:
The positioning blocks serve as intermediary components between the machine base and the die holders. These intermediaries absorb and distribute the dynamic forces generated during rapid reciprocating motion, protecting the alignment between die faces while enabling high-speed operation.
4Ease of operation
If modular positioning components are used, then ease of operation improves and training time decreases, but device complexity increases
Solution Approach 1:
The positioning blocks are designed as universal components that can be used with multiple different die holders and for various positioning requirements. This multi-functionality reduces the overall number of unique components needed in the system, simplifying inventory management and assembly while maintaining ease of operation.
Solution Approach 2:
The system uses positioning blocks with varying dimensional parameters (different thicknesses, widths, or profiles) to accommodate different positioning requirements. By changing the parameters of standard components rather than creating entirely different parts, the system maintains simplicity while handling diverse positioning needs.
Data Source
AI summary
The present invention is a die positioning system for use in positioning mobile or fixed dies. The system includes a pair of key bars, a pair of key disc inserts, a set of key discs, and a set of disc backers. The key bars and key discs serve to offset manufacturing dies or die holders. Using key bars and/or key discs from different pairs of key bars and/or sets of key discs also allows for precise angulation of the dies or die holders. The key discs are held in place between the die and die holder, or between the die holder and key base, by the key disc inserts and angled (if feasible) by the disc backers. The key bars, located between the key disc inserts and the die or die holder allow additional offset of the die or die holder. The solid, stacked configuration of the key bars and key discs prevents the die or die holder from gradually or suddenly losing its positioning.