Quality Management

The aim behind the co-operation was to provide the operator with reliable, predictive and easily comprehensible information about the thread rolling process in the set-up and production phase. By providing clear operating instructions, Brankamp`s process-monitoring system makes it possible to perform set-up more quickly and considerably more efficiently. At the same time, the working lifetime of the thread roll jaws is increased and the machine load is reduced. Then the Brankamp developers had to determine the perfect measuring point of the sensors. „It`s in the jaw holder“, according to Franz Saliger, engineer and authorised representative for Brankamp. „Because it supports the adjusting screws, the patented sensor developed especially for monitoring thread rollers measures the full rolling pressure as the part is fed in and out.“ Measuring points to date couldn`t provide the operator with accurately reproducible measurements. Not only that, but they also presented a number of disadvantages: In signal recording, and thus in fault recognition, and also in mounting the sensors and running the cabling. The advantages of Brankamp senors include maximum fault recognition capability, easy mounting and protected cable routing.
Using innovative Brankamp thread roller monitoring, the thrust-carrying member sensor can for the first time ever be calibrated. The operator can then read off the absolute rolling forces for the feed and output side to top and bottom. As a result, adjustment errors during the set-up phase, and the associated increased machine wear, can be reduced to a minimum.

True tracking precision

A further critical point when setting up the thread roller is accurate alignment of the tracking between the fixed and the moveable roll jaw. Even if this alignment is still accurate when the machine is static, it changes as soon as the thread roller is in continuous use. Without ProcessMonitoring the operator must carry out follow-up tracking adjustment, in a time-consuming process. Brankamp has developed the tracking sensor specifically to address this problem. The patented sensor records precisely the tracking.

Comprehensive practical tests

The two Brankamp innovations have proven their worth in exacting and extensive practical tests. The Erkrath-based company is now offering complete solutions for thread rolling in the form of its PK4U and PK 6000 models.
Stand 14 D32

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