Wire Thread Insert Spindle Control With Decoupled Rotation and Feed
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automatic installation machines for wire thread inserts in thread bores of components are inefficient due to the need for complex gear drives and pneumatic systems, which complicate the installation process and increase cycle times.
Innovation Solution
An automatic installation machine with a rotating drive unit capable of switching between two rotation directions, combined with a pneumatic cylinder for axial displacement and a decoupling mechanism allowing independent control of rotation and linear movements, simplifies the installation process by separating torque transmission from axial displacement, enabling efficient installation and removal of wire thread inserts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a gear drive is used to transmit rotation from the engine to the mandrel, then the installation machine can achieve controlled rotational movement, but the device complexity increases
Solution Approach 1:
The patent extracts the gear drive from the system and replaces it with a direct connection between the engine and mandrel. The engine's rotation is directly transmitted to the mandrel without intermediary gear mechanisms, thereby reducing device complexity while maintaining rotational speed control through electronic means.
Solution Approach 2:
The patent replaces the mechanical gear drive system with an electronic control system. The engine's rotational output is directly coupled to the mandrel, and speed control is achieved through electronic regulation of the engine itself rather than mechanical gear changes, substituting a complex mechanical transmission system with a simpler electronically controlled direct drive.
2Extent of automation
If a pneumatic cylinder is used for breaking the installation tang, then the breaking operation can be automated, but the device complexity increases
Solution Approach 1:
The patent merges the tang breaking function into the existing mandrel structure. The mandrel itself is designed with a breaking edge that directly breaks the tang during the withdrawal operation, combining the breaking function with the existing installation and withdrawal mechanism rather than adding a separate pneumatic breaking system.
Solution Approach 2:
The mandrel is designed to perform the tang breaking operation automatically during its normal withdrawal motion. As the mandrel is pulled out of the component, its breaking edge naturally contacts and breaks the tang without requiring any additional actuation systems, making the system self-sufficient and eliminating the need for external pneumatic breaking equipment.
3Device complexity
If the engine rotation is directly transmitted to rotate the wire thread insert, then the installation process is simplified, but the axial displacement control becomes more difficult
Solution Approach 1:
The patent segments the motion control into two independent parts: rotational movement is controlled by the engine directly driving the mandrel, while axial displacement is controlled by a separate linear actuator. This segmentation allows each function to be optimized independently - simple direct drive for rotation and precise positional control for axial movement - thereby simplifying the overall system while maintaining ease of operation.
Solution Approach 2:
The patent introduces a linear actuator as an intermediary mechanism between the control system and the mandrel for axial displacement control. This intermediary device specifically handles the axial positioning function, allowing the engine to focus solely on rotational control, thus simplifying the overall control architecture while maintaining precise axial displacement capability.
4Adaptability or versatility
If complex gear drives and pneumatic systems are used, then the installation machine can perform multiple functions, but the cycle time increases
Solution Approach 1:
The patent employs dynamic control of the engine, allowing it to operate at variable speeds throughout the installation cycle. The engine can rotate rapidly during installation phases and slow down or reverse for withdrawal and breaking operations, enabling multiple functions to be performed sequentially without requiring separate dedicated mechanisms for each function, thereby reducing overall cycle time while maintaining versatility.
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 configuration reduces cycle times and simplifies the installation process by allowing independent control of rotational and linear movements, improving the efficiency and effectiveness of wire thread insert installation in thread bores.
Implementation Method 1
a thread connection between the mandrel and a sleeve with inner thread converts the rotation of the engine into a straight-lined installation movement
Implementation Method 2
a first actuating member, which may be a pneumatic cylinder with an axially movable piston
Implementation Method 3
the outer diameter of the cylindrical helix of the wire thread insert must be chosen slightly bigger than the inner diameter of the receiving thread of the component. It is guaranteed by that that due to the elastic recovery of the wire thread insert after the installation in the receiving thread, a firm fit of the wire thread insert is achieved
Data Source
AI summary
An automatic installation machine, which is connectable to a tool so as to install a wire thread insert in a thread bore, includes a drive unit providing movement between a first and a second rotation direction, a setting spindle in rotation coupling with the drive unit so that during a transmission of a rotation movement from the drive unit, the setting spindle is displaceable in longitudinal direction independent of the rotation movement. A first pneumatic cylinder has a movable piston oriented parallel to the longitudinal direction of the setting spindle and coupled with an offset with the setting spindle so that the setting spindle is axially displaceable by the pneumatic cylinder. An actuating mandrel is arranged within the setting spindle and is driven rotation free, and the installation machine includes a tool chuck via which the tool for installing the insert is connectable with the setting spindle.