The raw materials used in cold heading machines primarily include coiled stock and bar stock. During production, the length of raw materials cannot be an exact integer multiple of individual blank lengths, inevitably leaving residual stub ends. Particularly when using bar stock, the joint between two sequentially fed bars generates material ends at both head and tail sections. These residual ends pose significant hazards:
1. Increased risk of die damage
2. Potential impairment to transfer clamps
3. Accelerated wear of cutting tools
4. Material waste
Technical Solution
1. Bar Joint Detection Mechanism
During bar stock feeding, the detection mechanism identifies the joint between consecutive bars (where the tail of the preceding bar connects to the head of the following bar) and sends a signal to the control system. Traditional methods rely on limit switches and mechanical linkages to detect bar ends. This innovation introduces a color mark sensor for joint detection. By marking the joint with a distinctive color, the sensor identifies the joint position via chromatic recognition and triggers a signal upon detection, enabling precise joint localization.
2. Bar Length Tracking & Measurement System
Upon receiving the joint detection signal, the control system activates a tracking mechanism to measure the feed length in real time, dynamically calculating the distance between the detected joint and the cutting blade. When the feed length equals the preset distance between the detection point and the blade, the system activates the end-separation mechanism.
Operating Principle: A tracking wheel, driven by the linear motion of the bar stock, rotates in sync with the feed. A rotary encoder coupled to the wheel converts rotational displacement into pulse signals. The control system processes these pulses to compute real-time feed distances, enabling accurate tracking of the joint's position relative to the cutting blade.
3. Head/Tail Separation Mechanism
When the joint reaches the cutting blade, the blade severs the residual end (head/tail). Simultaneously, a pneumatic cylinder actuates to open the material gripper, preventing it from clamping the severed end. The residual segment then falls into a waste container, achieving complete separation of defective ends from qualified products.
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