Thread Rolling Machine with Optical Feedback Control
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Solution Overview
Problem
Current rolling machines for forming threaded portions on cylindrical bodies require lengthy calibration times, lack precision, and are operator-dependent, leading to high costs and variability in quality due to complex adjustments and material-specific challenges.
Innovation Solution
A rolling machine with a feedbacked forming process that uses sensors and actuators to precisely control the position and tilt of forming rollers, aided by a logic control unit and structured light for real-time measurement and adjustment, ensuring accurate thread formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment and calibration of forming rollers is used, then the machine can be operated with simple equipment, but the calibration time is lengthy and manufacturing precision is poor
Solution Approach 1:
The patent implements a feedback mechanism where sensors detect the actual position and tilt of forming rollers, and the control unit automatically adjusts them to match the predetermined values. This closed-loop feedback system eliminates manual calibration time while ensuring high manufacturing precision for thread formation.
Solution Approach 2:
The patent replaces manual mechanical adjustment with an automated control system that uses sensors, actuators, and a control unit to precisely position and tilt the forming rollers. This substitution of mechanical manual operation with automated control system achieves both time efficiency and precision.
2Manufacturing precision
If manual adjustment of forming rollers is used, then the device complexity is low, but the operation depends on operator skill leading to quality variability
Solution Approach 1:
The control system continuously monitors the actual position and tilt of forming rollers through sensors and compares them with predetermined values, automatically making adjustments to maintain precision. This feedback mechanism eliminates operator skill dependency while managing device complexity through automated control.
Solution Approach 2:
The system performs self-adjustment of forming roller positions and tilts based on sensor feedback and predetermined values, eliminating the need for operator intervention. This self-service capability ensures consistent quality without requiring skilled operators, managing complexity through automation.
3Reliability
If multiple forming rollers are used to distribute compression forces, then the reliability of the process improves, but the adjustment complexity increases
Solution Approach 1:
The control system independently controls the position and tilt of each forming roller through individual sensors and actuators, ensuring that all rollers are precisely positioned to distribute compression forces evenly. This feedback-controlled approach maintains process reliability while managing the complexity of multiple roller adjustments.
Solution Approach 2:
The control system uses a universal control unit that manages all forming rollers through standardized sensors and actuators, applying the same control logic to each roller. This multi-functional approach handles the complexity of multiple rollers systematically, ensuring reliable force distribution across all rollers.
4Manufacturing precision
If precise phasing and tilting of forming rollers is performed manually, then the manufacturing precision can be achieved, but the ease of operation deteriorates
Solution Approach 1:
The control system automatically adjusts the phasing and tilting of forming rollers based on sensor feedback and predetermined values, eliminating complex manual adjustments. This feedback mechanism achieves precise thread profiles while dramatically improving ease of operation by removing manual calibration burden.
Solution Approach 2:
The patent replaces manual mechanical adjustment of roller phasing and tilting with an automated control system that uses sensors and actuators to precisely position each roller. This substitution achieves high manufacturing precision while greatly improving ease of operation through automation.
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 solution enables precise, efficient, and cost-effective production of high-quality threaded portions by automatically adjusting the forming rollers based on real-time feedback, reducing calibration time and operator dependency.
Implementation Method 1
the machine also comprises projection means mounted on the support structure and projecting a light pattern substantially towards the work axis A in a manner such as to interfere with the external surface of the cylindrical body to be formed
Implementation Method 2
which are susceptible of detecting a reflected light from the cylindrical body itself indicative of a profile of the thread of the same cylindrical body
Implementation Method 3
Calculation means are also provided that are connected with a signal cable (or with another data communication connection means) to the sensor means in order to process the images detected thereby
Implementation Method 4
The present rolling machine and the process are inserted in the industrial field of precision mechanical machining achieved by means of cold plastic deformation
Implementation Method 5
each forming roller is also driven to be moved by a corresponding actuator along a transverse axis substantially perpendicular to the work axis in order to impart, by means of compression, with its threaded portion, an impression of the metal body to be formed
Implementation Method 6
Motor means are furthermore provided, arranged on the support structure and mechanically connected to the forming rollers in order to drive them in rotation abutted against the cylindrical body to be formed
Data Source
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AI summary
Improved rolling machine for forming a threaded portion on cylindrical bodies, which comprises two or more forming rollers (6) provided with a threaded portion and drivable to rotate on the surface of a cylindrical body to be formed in order to make a corresponding threaded portion thereon. The machine comprises generator means (41) projecting a lighting pattern (42) susceptible of interfering with the external surface of the cylindrical body (50) to be formed, in order to generate a reflected light beam (43) indicative of the profile of the thread (8) already formed on the cylindrical body (50). Such light beam is captured by first sensor means (30) which communicate with calculation means (44) in order to process the images of the sensor means and obtain measurements of the profile of the thread (8) to be compared with sample measurements of a stored sample profile. In case of deviations, a logic control unit (45) drives at least one of the actuator means (15, 16, 40) responsible for adjusting the position of the single forming rollers (6) with respect to the cylindrical body to be formed (50) in order to restore the threaded portion in accordance with the design data.