CROSS-REFERENCE TO RELATED APPLICATIONS

[0001 ] This application claims the benefit of prior-filed, co-pending U.S. Provisional Patent Applications Nos. 62/723,246, filed on August 27, 2018, and 62/801 ,966, filed on February 6, 2019, the contents of which are incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

[0002] The present disclosure is directed to a system for mechanical die-based manufacture of threaded fasteners.

[0003] Thread rolling to manufacture bolts, screws, and other threaded fasteners requires rapid rolling of fastener blanks between a mobile die and a stationary die to form the thread. The manufacturing apparatus reciprocates the mobile die back and forth relative to the stationary die at a high rate of speed, often hundreds of reciprocations in a minute. Because many different blank and thread configurations may be used with and required from one manufacturing apparatus, numerous different dies can be interchangeably used with the same machine. While switching out dies may change the thread patterns, accommodating the different size and shape of the blanks usually falls to the die holders of the apparatus. Such holders typically include an adjustment mechanism which can alter the location and angulation of the dies to accommodate different blanks. [0004] All current manufacturing equipment requires adjustment to the pressure and distance between the faces of the dies, and occasionally the angulation of one or both of the dies. The industry’s standard practice uses a threaded adjustment to properly position the die faces. Operators may require several years of training to learn the appropriate“feel” required for current adjustment methods to produce good fasteners, often resulting in unusable batches of product during the long training period. Furthermore, such adjustment mechanisms can be shifted out of position accidentally or over the course of production. Moreover, due to the rapid reciprocating movement of the mobile die and its respective mobile die holder, as well as the cantilevered positioning of the mobile die holder on the apparatus, the mobile die holder may be subject to forces which move it out of alignment, creating further waste of time and material.

[0005] It is therefore the object of this application to provide a die positioning system which provides accurate, easily reproducible positioning of at least one die and its corresponding die holder over long periods of high use.

BRIEF SUMMARY

[0006] One embodiment of the present invention is a die positioning system including a pair of key bars, a pair of key disc inserts, a set of key discs, and a set of disc backers. Each key bar of the pair of key bars has a solid rectangular cuboid configuration identical to the other key bar of the pair of key bars. Each key disc insert has at least one disc aperture extending therethrough. Each key disc of the set of key discs has a solid three-dimensional configuration identical to the other key discs of the set of key discs, with each key disc having a diameter equal to or less than a diameter of the disc aperture. The forward surface of each disc backer includes a backer surface having a non-planar configuration.

[0007] Another embodiment of the present invention is a die positioning system including multiple pairs of key bars, at least one pair of key disc inserts, multiple sets of key discs, and at least one set of disc backers according to the system shown above.

[0008] Another embodiment of the present invention is a die positioning system including at least one pair of key bars, at least one pair of key disc inserts, at least one set of key discs, and at least one set of disc backers according to the system shown above. The system also includes a plurality of roller bearings mounted to a base slide and at least one slide rail mounted to a moving slide. The mounted slide has a line of motion, with the roller bearings is mounted to the base slide such that the axis of rotation of each of the roller bearings is orthogonal to the line of motion. The slide rail receives at least two of the roller bearings such that at least one roller bearing contacts an upper inner surface of slide rail and another roller bearing contacts a lower inner surface of the slide rail.

BRIEF DESCRIPTION OF THE DRAWING(S)

[0009] Figures 1 a and 1 b depict perspective views of one embodiment of a key system and a disc adjustment assembly for use in a die positioning system. Figures 1 c and 1 d depict partial perspective and partial cross-sectional views, respectively, of the embodiments of the key system and the disc adjustment assembly in use. [0010] Figure 2a depicts a perspective view of another embodiment of the key system and the disc adjustment assembly. Figure 2b depicts a partial cross-sectional view of the embodiment of the key system and the disc adjustment assembly in use.

[001 1 ] Figures 3a, 3b, and 3c show partial perspective, cross-sectional, and exploded views, respectively, of a bearing assembly which may be used in conjunction with, or separately from the key system and the disc adjustment assembly.

[0012] It should be understood that for clarity, not every part is labeled in every drawing. Lack of labeling should not be interpreted as a lack of disclosure.

DETAILED DESCRIPTION OF THE INVENTION

[0013] In the present description, certain terms have been used for brevity, clearness and understanding. No unnecessary limitations are to be applied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes only and are intended to be broadly construed. The different systems and methods described herein may be used alone or in combination with other systems and methods. Dimensions and materials identified in the drawings and applications are by way of example only and are not intended to limit the scope of the claimed invention. Any other dimensions and materials not consistent with the purpose of the present application can also be used. Various equivalents, alternatives and modifications are possible within the scope of the appended claims. Each limitation in the appended claims is intended to invoke interpretation under 35 U.S.C. §1 12, sixth paragraph, only if the terms“means for” or“step for” are explicitly recited in the respective limitation. [0014] Figures 1 a and 1 b present perspective views of one embodiment of key system 1 10 for use in a die positioning system 100. Each key system 1 10 includes a plurality of pairs of key bars 1 1 1 , a plurality of sets of key discs 1 12, and at least one pair of key disc inserts 1 13. In the exemplary embodiment of Figure 1 a, system 100 includes 13 pairs of key bars 1 1 1 , 15 sets of key discs 1 12, and one pair of key disc inserts 1 13. Other embodiments may include more or fewer pairs of key bars 1 1 1 , sets of key discs 1 12, and pairs of key disc inserts 1 13.

[0015] Each key bar 1 1 1 of each pair of key bars 1 1 1 is a solid rectangular cuboid having an identical thickness within the pair, but differing from the thickness of other pairs of key bars 1 1 1 in the key system 1 10. Pairs of key bars 1 1 1 typically differ in thickness at increments of approximately 0.01 inches, though other increments are possible. Each pair of key bars 1 1 1 may be uniquely marked within the key system 1 10 by alphanumeric and/or colored indicia for identification and separation from other pairs of key bars 1 1 1 .

[0016] Each key disc 1 12 of each set of key discs 1 12 is a solid three-dimensional shape having an identical thickness within the set, but differing from the thickness of other sets of key discs 1 12 in the key system 1 10. While the key discs 1 12 shown in the instant figures are cylindrical, other three-dimensional shapes, such as cuboids, cubes, hemispheres, prisms, and/or any combination thereof, are contemplated and encompassed by the claims of this application. Sets of key discs 1 12 typically include four key discs 1 12, though other embodiments may use more or fewer key discs 1 12. Sets of key discs 1 12 typically differ in thickness at increments of approximately 0.001 inches, though other intervals are possible. Each set of key discs 1 12 may be uniquely marked within the key system 1 10 by alphanumeric and/or colored indicia for identification and separation from other sets of key discs 1 12. Sets of key discs 1 12 may be used completely or may be“mixed and matched” with key discs from another set to angle a stationary die D or a mobile die D.

[0017] Each key disc insert 1 13 includes at least one disc aperture 1 14 designed to receive and hold a single key disc 1 12. The key aperture 1 14 has a diameter greater than the key disc 1 12, and a shape conforming to the outer periphery of the key disc 1 12. In the exemplary embodiment of Figures 1 a and 1 b, each key disc insert 1 13 includes two disc apertures 1 14, though other embodiments may use more or fewer key disc apertures 1 14. Each key disc insert 1 13 has a stepped configuration between a thicker section and a thinner section. The thinner section is equal in thickness to or thinner than the thinnest set of key discs 1 12 to allow proper biasing using each set of key discs 1 12 in the key system 1 10. The thicker section extends above the die holder H with the step holding the key disc insert 1 13 in place vertically with respect to the die D and the die holder H. In certain embodiments, at least one magnet aperture 1 15 extends through a sidewall of each disc aperture 1 14 to accommodate at least one capture magnet 1 16. The capture magnet 1 16 helps to hold the key disc 1 12 in place in the disc aperture 1 14, as the key discs 1 12 can be made from a ferromagnetic or ferrimagnetic material.

[0018] In use, as can be seen in Figures 1 c and 1 d, at least one recess within the die holder FI receives a pair of key bars 1 1 1 and a pair of key disc inserts 1 13 in the space between the die D and the die holder FI. The key disc inserts 1 13 hold at least one set of key discs 1 12. One key bar 1 1 1 of the pair of key bars 1 1 1 and one key disc insert 1 13 of the pair of key disc inserts 1 13 extends along a first end of one side of the die D, while the other key bar 1 1 1 of the pair of key bars 1 1 1 and the other key disc insert 1 13 of the pair of key disc inserts 1 13 extends along a second end of the same side of the die D, as can be seen in Figure 1 d. In the embodiment of Figures 1 a through 1 d, the position of the die D can thereby be adjusted in increments of approximately 0.01 inches by changing the key bars 1 1 1 used, and adjusted in increments of approximately 0.001 inches by changing the key discs 1 12 used.

[0019] If a user wishes to create a vertical or horizontal angle for the surface of the die D, they may combine the key discs 1 12 from different sets. For vertical angulation, the thicker key discs 1 12 are typically placed in lower disc apertures 1 14, though reversal is possible. By way of non-limiting example, if a first set of key discs 1 12 has a thickness of approximately 0.031 inches and a second set of key discs 1 12 has a thickness of approximately 0.041 inches with a distance between center points of the disc apertures 1 14 of approximately 0.5 inches, the surface of the die D will have an angulation of approximately 1 .1 degrees from vertical if using the thinner key discs 1 12 in the upper disc apertures 1 14. It is contemplated that the key discs 1 12 from any number of different sets of key discs 1 12 may be used to create vertical and/or horizontal angulation of the die D, depending upon the desired angulation and number of the key discs 1 12 which can be used within the die positioning system 100.

[0020] Each key system 1 10 can be used with either a stationary or a mobile die D. Because most manufacturing apparatuses include both stationary and mobile dies D, two key systems 1 10 may be used, one for each die D. Referring back the above example, doubling the angulation, that is, providing similarly differentiated key discs 1 12 in the key disc inserts 1 13 for both the mobile and stationary dies D, will result in a fastener having a taper of approximately 2.2 degrees. [0021 ] As shown in Figures 1 b through 1 d, a disc adjustment assembly 120 allows the key system 1 10 to be stabilized at any angle. Within the assembly 120, sets of disc backers 121 interact with sets of key discs 1 12 to allow the key discs 1 12 to extend at an angle relative to the plane of the die holder H. While the embodiment shown in Figure 1 b includes four disc backers 121 , sets with more and fewer disc backers 121 are contemplated to interact with the same number of key discs 1 12.

[0022] The disc backers 121 have backer surfaces 122, non-planar forward surfaces which are placed behind the key discs 1 12. In the embodiment shown in Figure 1 b and 1 d, the backer surfaces 122 at the front of disc backers 121 have a domed, convex configuration allowing at least partial rotation of the key discs 1 12 about at least three axes. In other embodiments, the backer surfaces 122 have a spherical or at least partially spherical convex configuration with complementary concave mating surfaces on the backs of the key discs 1 12, also allowing at least partial rotation of the key discs 1 12 about at least three axes. The reverse may also be true, with the backer surfaces 122 having a spherical or at least partially spherical concave configuration with complementary convex mating surfaces on the backs of the key discs 1 12. In certain other embodiments, the backer surfaces 122 have a convex angled configuration, allowing at least partial rotation of the key discs 1 12 about two axes. All of these configurations prevent the disc backers 121 from exerting a force on an edge of the key discs 1 12, preventing deformation of the key discs 1 12.

[0023] Figures 1 c and 1 d also present perspective and partial cross-sectional views, respectively, of one embodiment of a die clamp assembly 130 for use in the die positioning system 100. In the clamp assembly 130, a clamp top 131 removably secures the die D to a clamp base 135. A backplate 132 extending between the clamp top 131 and the clamp base 135 includes at least two lateral back flanges 133 to either side. Each back flange 133 includes at least one backer aperture 134 aligned with a disc aperture 1 14 on the key disc inserts 1 13. The disc backers 121 extend at least partially through each backer aperture 134. When the key discs 1 12 are used in system 100, the backer surface 122 at the forward surface of each disc backer 121 contacts a back surface of the key disc 1 12, allowing the key disc 1 12 to have an adjustable angle with respected to the vertical backplate 132, resulting in a better-supported angulation of the key bars 1 1 1 .

[0024] A raised base surface 136 on the upper surface of the clamp base 135 also enables additional stability in clamping the die D by allowing angulation for the die D between the clamp top 131 and the clamp base 135. Because the raised base surface 136 extends parallel to yet set back from the forward edge of the clamp base 135, the die D may be angled inwardly or outwardly. The raised base surface 136 extends behind a first clamp base surface 137a and in front of a second clamp base surface 137b. Because both clamp base surfaces 137a and 137b are lower than the raised base surface 136, the die D may be angled with either a forward or backward slope, depending on the arrangement of the key discs 1 12.

[0025] Clamping the die D securely when using the key bars 1 1 1 and the key discs 1 12 requires special geometry so the system 1 00 works at any angle created by having a different key disc 1 12 and/or key bar 1 1 1 in the system 100 creating a taper. A difference in the diameter at the top and bottom of the part being rolled or special geometry require distance adjustments between the top and bottom of the die D. The disc backers 121 have a fixed distance apart; knowing this distance allows the calculation of the correct combination of key discs 1 12 and/or key bars 1 1 1 for each part. The backer surface 122 on the front of each disc backer 121 allows the key discs 1 12 to incline and align more effectively with the key bars 1 1 1 and the die D.

[0026] The raised central geometry of the raised base surface 136 on the clamp base 135 enables the die D to be clamped down securely. If the upper surface of clamp base 135 was flat, the die D would have tendency to straighten when clamped by the clamp top 131 . Clearance is required on the left and right of this surface. Because the angle produced by the key discs 1 12 of differing thickness may be positive or negative, the raised base surface 136 is raised in the center, as seen in Figure 1 c. The central rise allows the die D to slope inwardly from the top or outwardly from the top, depending on whether the top or bottom key disc 1 12 is thickest, respectively.

[0027] Figure 2a presents a perspective view of another embodiment of the disc adjustment assembly 120 for use with the key system 1 10. This embodiment of the disc adjustment assembly 120 includes the previously-discussed disc backers 121 , and adds a plurality of datum spacers 123 and a plurality of draw bolts 124. Each datum spacer 123 receives at least part of a disc backer 121 at one end and receives at least part of the threaded draw bolt 124 through its opposite, threaded end.

[0028] Figure 2b presents a cross-sectional view of the above embodiment of disc adjustment assembly 120 in use. In use, this embodiment of the assembly 120 is not placed between the die D and the die holder H, but between a key base K and the die holder H. As a result, the entire die holder FI is angled and/or offset instead of just the die D. The die holder FI is supported by a die holder rest Fir, which allows proper angulation of the die holder FI, similarly to the way in which the raised base surface 136 allows angulation of the die D in Figure 1 c. While the die holder rest Hr has a circular cross-section in the embodiment of Figure 2b, other cross-sectional configurations allowing angulation of the die holder H are contemplated.

[0029] Each datum spacer 123 in located in a stepped bore within the key base K. The draw bolt 124 extends from the back of the key base K through the narrower section of the bore and into the datum spacer 123 to hold the datum spacer 123 in place within the key base K. The datum spacer 123 is located in the wider section of the bore, along with the disc backer 121 . Part of the disc backer 121 extends into the datum spacer 123 to hold the disc backer 121 in place within the key base K. In the embodiment of Figure 2b, four datum spacers 123 are used; other embodiments may have more or fewer datum spacers 123. The datum spacers 123 extend parallel to each other; their longitudinal axes are parallel in XY and YZ planes.

[0030] The various embodiments of the key system 1 10 and the disc adjustment assembly 120 may be retrofit onto/into existing dies D and manufacturing devices. The combination of alphanumeric and/or colored indicia from the pair(s) of key bars 1 1 1 and the set(s) of key disc inserts 1 13 which are used with a particular die and/or manufacturing apparatus to create a particular type of fastener may be recorded and provided in a standardized listing of combinations. In certain embodiments, one of the key bars 1 1 1 and the key disc inserts 1 13 may have alphabetical indicia and the other of the key bars 1 1 1 and the key disc inserts 1 13 may have numerical indicia to facilitate easier identification. In certain embodiments, the type of fastener to be manufactured may be entered into a computer program, along with the die(s) and/or manufacturing apparatus to be used. Software algorithms may use the information to retrieve a known combination or extrapolate potential combinations from known combinations.

[0031 ] Figures 3a, 3b, and 3c show perspective, cross-sectional, and exploded views, respectively, of a bearing assembly 140 which may be used in the system 100 in conjunction with, or separately from the key system 1 10 and the disc adjustment assembly 120. Whether using a linear bearing or other bearing means for manufacturing threaded fasteners, it is critical that the apparatus does not oscillate vertically (up or down along the vertical axis of the fasteners, as can be seen in Figure 3b, represented by dashed lines). All fastener blanks, especially metric or English machine fastener blanks, must have a consistent helix angle. If the helix angle varies at all, the performance of the fastener is hampered. In the art, this is called a drunken thread. Making this more complicated is the fact that all bearings, including linear bearings, require clearance (also known as play) to operate, which may result in unwanted oscillation in a direction orthogonal to the direction of motion. In certain embodiments of the die positioning system 100, a bearing assembly 140 can be added directly to a linear bearing assembly A with a reciprocating mobile die holder FI to prevent this from happening. When using a linear bearing and a rack and pinion system this additional stability is a requirement to prevent a drunken thread.

[0032] As shown in Figures 3a, 3b, and 3c, the linear bearing assembly A includes three elements to make up a working assembly A. A base slide B is connected directly to the machine base and is stationary. The base slide B includes a stationary bearing rail Rs. In the case of a linear bearing assembly 140, a center subassembly C contains two sets of linear bearings L1 and L2 opposing each other. The center subassembly C is positionally controlled by a pinon gear P that interacts with the base slide B and a moving slide M. The moving slide M contains an additional moving bearing rail Rm.

[0033] At least one bearing assembly 140 is used in the linear bearing assembly A to prevent oscillation. Each bearing assembly 140 also includes at least three elements. A plurality of roller bearings 141 are directly attached to the base slide B or the machine base. While the embodiment shown in Figures 3a through 3c includes at least two roller bearings 141 a and 141 b, other embodiments may include more roller bearings 141 . At least one slide rail 142 is directly attached to mobile slide M. When the base slide B, the center subassembly C, and the moving slide M are in normal operation, the roller bearings 141 a and 141 b directly support the moving slide M via the slide rail 142, preventing the moving slide M from experiencing any vertical oscillation. Because the roller bearings 141 can operate at normal manufacturing rates and pressures exerted during thread forming operations, the roller bearings 141 will not affect manufacturing speed for the linear bearing assembly A.

[0034] The roller bearings 141 and the slide rail 142 may be retrofit onto existing linear bearing assemblies A. The roller bearings 141 have diameters smaller than the inner diameter of the slide rail 142. In various embodiments, the roller bearings 141 can include caged ball bearings, cylindrical roller bearings, spherical roller bearings, and/or tapered roller bearings. In certain embodiments, the roller bearings 141 are vertically offset from each other to provide specific support along the upper inner surface of the slide rail 142 and the lower inner surface of the slide rail 142, respectively. [0035] It is to be understood that this written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make anew the invention. The various embodiments of the invention may be combined in any arrangement capable of manufacturing threaded fasteners. Any dimensions or other size descriptions are provided for purposes of illustration and are not intended to limit the scope of the claimed invention. Additional embodiments can include slight variations, as well as greater variations in dimensions as required for use in the industry. The patentable scope of the invention may include other examples that occur to those skilled in the art.