Thread-Rolling Die Distance Sensing for Vibration-Induced Misalignment
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Solution Overview
Problem
Conventional thread-rolling machines face issues with die loosening and displacement due to high-speed movement and vibration, leading to quality control challenges and increased defective products, especially in automated environments where manual inspection is inadequate.
Innovation Solution
A thread-rolling apparatus with a distance-sensing assembly that includes sensing units and a processing module to non-contactly measure and adjust the distance between dies, ensuring the working passage maintains its initial setting condition, thereby enhancing the yield rate and quality of thread-rolling operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual inspection is used to monitor die distance, then operational simplicity is maintained, but quality control efficiency deteriorates and defective products increase
Solution Approach 1:
The patent replaces manual inspection with an optical sensing system. A light source emits light that reflects off the die surface, and a photodetector measures the reflected light intensity to determine die distance and position, substituting mechanical/manual monitoring with an optical measurement system.
Solution Approach 2:
The patent introduces light as an intermediary medium to transmit information about die position. The light reflects off the die and carries positional information to the photodetector, enabling indirect measurement of die distance without direct physical contact or manual intervention.
2Adaptability or versatility
If pressure detection is used to monitor die position, then some adjustment capability is provided, but immediate detection of die distance changes is insufficient
Solution Approach 1:
The patent replaces pressure-based detection with optical detection. Instead of measuring force or pressure changes, the system uses light reflection intensity to directly measure die position and distance changes, providing more immediate and precise detection.
Solution Approach 2:
The patent establishes a reference light intensity value corresponding to the correct die position before operation. During operation, the system continuously compares current light intensity against this pre-established reference to immediately detect any deviations in die position.
3Productivity
If multiple machines are operated synchronously with one operator, then automation level increases, but quality control effectiveness deteriorates
Solution Approach 1:
The patent enables the system to self-monitor and self-adjust die position automatically. The sensing system continuously measures die distance and triggers adjustment mechanisms when deviations are detected, allowing the machine to maintain itself without constant operator intervention.
Solution Approach 2:
The patent implements a closed-loop feedback system where the photodetector continuously monitors die position and feeds this information back to the control system, which then activates adjustment mechanisms to correct any deviations, maintaining continuous quality control across multiple machines.
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
The apparatus effectively detects and adjusts for variations in die distance in real-time, reducing defective products and increasing the efficiency of thread-rolling operations by preventing improper distance changes, thus improving the overall quality and yield rate.
Implementation Method 1
The sensing unit is configured to sense the first distance in a non-contact manner and to generate corresponding numeral data
Data Source
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AI summary
A thread-rolling apparatus (3) includes a base (31), a feeding unit (32), a thread-forming assembly (33), and a distance-sensing assembly (34) . The base (31) mainly includes a movable portion (311), a first body (312a), and a second body (312b) between the movable portion (311) and the first body (312a) . The thread-forming assembly (33) includes cooperating first and second dies (331, 332) and a working passage (333) formed between the dies (331, 332). The distance-sensing assembly (34) includes at least one sensing unit (341) disposed on the first body (312a) and a processing module (342) connected to the sensing unit (341) . The cooperation between the sensing unit (341) and the processing module (342) senses changes in a first distance (D1) between the first body (312a) and the second body (312b) in a non-contact manner whereby abnormal variations can be quickly observed and properly coped, and a second distance (D2) of the working passage (333) can be in a normal state. Accordingly, the yield rate of the thread-rolling apparatus (3) can be efficiently increased.