Technical Field
The present invention relates to a rolling machine and a method of rolling a gear
using the rolling machine. More specifically, the present invention relates to a rolling
5 machine that enables various components to be manufactured by rolling and a rolling
machine that corrects a tooth trace and the like of the gear with the rolling machine and a
method of rolling a gear using the rolling machine.
Background Art
In general, in gear machining by a machine tool, after machining by cutting,
10 grinding, and the like, a pitch error, a tooth shape error, a tooth trace (a crossing line of a
tooth surface and a pitch surface) error, and the like of the gear are measured by a gear
measuring device, an error due to the machine tool or a tool is found by data of the
measurement, and the machine tool or the tool is correctly adjusted. Usually, when a
gear is molded through rolling by a round die, after trial rolling, the rolled gear is
15 measured by a gear measuring device, the round die is redesigned and reground according
to an error obtained by the measurement, and a desired tooth shape of the gear is obtained
with high accuracy.
There are various profile deviations of gears. Helix deviations are specified by
the Japan Industrial Standard (JIS) as well. By measuring helix deviations in the gear
2 0 measuring device, for example, in the case of a spur gear, it is possible to measure an error
of formation of a lead inclining with respect to a spur gear center axis by a helix, an error
of tapering of the helix, and the like. With the gear measuring device, it is also possible
to measure a shape of a crowning in which both ends of the spur gear are formed as slight
curved surfaces to be thinned. To correct these errors and the !ike, clamp bolts for fixing
2 5 a supporting table, a turning table, and the like, which support the round die, are loosened,
an angle is adjusted by an angle adjustment screw, and turning angles and positions of the
suppmting table, the turning table, and the like are adjusted in order to adjust a turning
angle on an inclined shaft (an A shaft) turned around a pushing-in direction (an X axis) for
pushing in the round die and a turning angle on a taper shaft (a B shaft) turned around a Y
3 0 ax1s. That is, an operator alternately repeats work for adjusting an attachment angle, a
2
position, and the like of the round die and performing trial turning again to modify a
desired helix.
When the turning angles arc adjusted, since the turning angles are very small
angles and the mass of the supporting table is large and a frictional force is also large, as
5 adjustment for moving the supporting table, fine adjustment is difficult because a load of
the supporting table is large and the supporting table easily bends. The adjustment needs
to be performed by operating a clamp bolt, an angle adjustment screw, a position
adjustment screw, and the like with a technique and a skill of a skilled person. The
accurate angle adjustment and position adjustment are not easy for a non-skilled person.
10 Conversely, it is also likely that an error is caused because the inclined shaft (the A shaft)
and the taper shaft (the B shaft can be moved and adjusted. There is a demand for
development of a rolling machine that can facilitate adjustment of the inclined shaft (the A
shaft) and the taper shaft (the B shaft) and can perform adjustment of a helix, a profile, and
the like actively making use of an adjustment function. On the other hand, the applicant
15 proposed a structure including four columnar guide surfaces in a guiding section (a guide
section) in order to avoid, as much as possible, deformation of a machine body during
rolling by a round die to which a high load is applied (see Patent Literature 1). In general,
in a rolling machine by a round die, to avoid deformation of a supporting table that
supports the round die, a bar material for deformation prevention called stay bolt is laid
2 0 over in an upper part between left and right suppmiing tables.
The four guiding sections of the rolling machine or a stay bolt structure has a
drawback in that a raw material, which is a workpiece to be rolled, is prevented from
being carried in/out because the guiding sections or the stay bolt becomes an obstacle.
However. for the rolling machine for the gear, it is undesirable to remove the guiding
2 5 guides or the stay bolt to reduce the rigidity of the machine body. Further, these rolling
machines are not always optimum as the rolling machine for the gear. That is, these
rolling machines have an angle adjusting function in the taper shaft (the B shaft) direction
important for the rolling of the gear but are manually adjusted and do not have an
automatic adjustment function. In the machining of the gear by the rolling machine in
3 0 the past, a tooth surface and the like of the gear to be rolled are different in a position in an
axial direction. Therefore, in order to correct the difference, there has been proposed a
3
method of adjusting a shape error of the tooth surface in the axial direction by regularly
and reversely rotating the round die (see Patent Literature 2). This method has a
drawback in that a machining time is long because the round die is reversely rotated.
The method equalizes the shape error in the axial direction and cannot perform fine
5 adjustment.
Citation List
Patent Literature
PTL I Japanese Patent Application Laid-Open No. Hll-285765
10 PTL 2 W02003/000442 AI
Summary of Invention
Technical Problem
15
The present invention has been devised in view of the circumstances in the past
and attains objects described below.
It is an object of the present invention to provide a rolling machine that can
adjust, with a control motor mechanism, a turning angle on an inclined shaft (an A shaft)
turned around a push-in direction (an X axis) of a round die and a turning angle on a taper
shaft (a B shaft) turned around a Y axis.
It is another object of the present invention to set a position of a guide surface
2 0 high and provide a rolling machine having high rigidity.
It is still another object of the present invention to provide a method of rolling a
gear using, in order to correct a helix deviations, a profile deviation, and the like of the
gear, a rolling machine that can adjust a turning angle on an inclined shaft (an A shaft)
turned around a push-in direction (an X axis) of a round die and a turning angle on a taper
2 5 shaft (a B shaft) turned around a Y axis.
Solution to Problem
In order to solve the problems, the prevent invention adopts means described
below.
A rolling machine according to the present invention I is a rolling machine
3 0 including: a plurality of cylindrical round dies disposed centering on a raw material, which
is a workpiece, to roll the raw material from the outer circumference of the raw material;
4
die-rotation driving means for driving to rotate the round dies; raw material supporting
means for rotatably supporting the raw material; and push-in means for bringing the round
dies close to each other from the outer circumference toward the raw material and pushing
in the round dies while rotating the round dies in the same direction in synchronization
5 with each other, the rolling machine fmther including: a B-shaft swinging table that
swings on a taper shaft (a B shaft) turning around a Y axis orthogonal to a push-in
direction (an X axis) of the round dies; a die table that swings on an inclined shaft (an A
shaft) turning around the push-in direction (the X axis) of the round dies on the B-shaft
swinging table; taper-shaft adjusting means for adjusting a swing angle of the B-shaft
10 swinging table on the taper shaft (the B shaft); and inclined-shaft adjusting means for
adjusting a swing angle of the die table on the inclined shaft (the A shaft).
In the rolling machine according to the present invention 2, m the present
invention 1, one of the round dies is mounted on a fixed headstock fixed on a bed, the
other of the round dies is mounted on a moving headstock that moves on the bed, and
15 guiding means on the bed of the moving headstock is a plurality of linear guide
mechanisms (7, 7, 9) having different heights in the vertical direction.
20
In the rolling machine according to the present invention 3, in the present
invention I or 2, the inclined-shaft adjusting means and the taper-shaft adjusting means
are means for correcting a helix and/or a profile of a gear.
In the rolling machine according to the present invention 4, in the present
invention 2, the plurality of linear guide mechanisms (7, 7, 9) are disposed at an equal
distance from a position of a power point in the push-in direction.
The rolling machine according to the present invention 5 includes, in the present
inventions I to 4, work-rotation driving means for rotating the raw material in
2 5 synchronization with the rotation driving of the round dies to control driving of rotation of
the raw material around the axis of the raw material.
In the rolling machine according to the present invention 6, in the present
inventions l to 4, the inclined-shaft adjusting means and/or the taper-shaft adjusting
means includes a shaft (105) driven by a numerically rotation-angle-controllable motor
30 (103) disposed on a fixed side, and is configured to bring a cam member (101), which
operates integrally with a moving object (1 07, 405) movable in the axial direction
according to rotation of the shaft (105), into contact with the die table (108) or the B-shaft
swinging table (60, 801) to numerically adjust a direction of the round dies.
5
In the rolling machine according to the present invention 7, in the present
inventions I to 4, the inclined-shaft adjusting means and/or the taper-shaft adjusting
means includes a shaft (76, I I 3, 802) driven to rotate by a numerically
rotation-angle-controllable motor (71, 112) disposed on a fixed side, and is configured to
5 bring an eccentric cam member (77, 1 I I, 804a, 804b), which operates according to the
rotation driving of the shaft (76, I I 3, 802), into contact with a cam follower (78, I 09,
806a, 806b) integral with the die table (21) or the B-shaft swinging table (60, 801) to
numerically adjust a direction of the round dies.
In the rolling machine according to the present invention 8, in the present
1 0 inventions I to 4, the inclined-shaft adjusting means and/or the taper-shaft adjusting
means includes gear transmission means (304, 305, 311, 312) driven by a numerically
rotation-angle-controllable motor (303, 307) disposed on a fixed side, and is configured to
rotate the die table (30I) or the B-shaft swinging table (60) according to a rotating motion
of the gear transmission means (304, 305, 311, 312) to numerically adjust a direction of
15 the round dies.
In the rolling machine according to the present invention 9, in the present
inventions I to 4, the inclined-shaft adjusting means and/or the taper-shaft adjusting
means includes a screw shaft (504) driven by a numerically rotation-angle-controllable
motor (502) disposed on a fixed side, includes a taper member (506, 508) screwed into the
20 screw shaft (504) and capable of advancing and retracting according to rotation of the
screw shaft (504), and is configured to press the die table (507) or the B-shaft swinging
table (60) according to a moving motion of the taper member (506, 508) to numerically
adjust a direction of the round dies.
In the rolling machine according to the present invention I 0, in the present
2 5 inventions I to 4, the inclined-shaft adjusting means and/or the taper-shaft adjusting
means includes a shaft (605, 707) driven by a numerically rotation-angle-controllable
motor (603, 705) disposed on a fixed side, is provided with, in the shaft (605, 707), two
eccentric members (60I, 703a, 703b) coming into contact with the die table (608, 701a,
70 I b) and spaced apati in the axial direction, and is configured to rotate the eccentric
30 members (601, 703a, 703b) according to rotation of the shaft (605, 707) to change an
eccentric distance, and press the die table (608, 701 a, 70 I b) or the B-shaft swinging table
(60) to numerically adjust a direction of the round dies.
6
A method of rolling a gear by a rolling machine according to the present
invention II is a method of rolling a gear by a rolling machine including: a plurality of
cylindrical round dies disposed centering on a raw material, which is a workpiece, to roll
the raw material from the outer circumference of the raw material; die-rotation driving
5 means for driving to rotate the round dies; raw material supporting means for rotatably
supporting the raw material; and push-in means for bringing the round dies close to each
other toward the raw material and pushing in the round dies while rotating the round dies
in the same direction in synchronization with each other, the method including: adjusting,
in order to correct a helix and/or a profile of the gear, a turning angle on an inclined shaft
10 (an A shaft) turned around a push-in direction (an X axis) of the round dies; and adjusting
a turning angle on a taper shaft (a B shaft) turned around a Y axis orthogonal to the axis of
the raw material.
In the method of rolling the gear by the rolling machine according to the present
invention 12, in the present invention II, the raw material is rotated in synchronization
15 with the rotation driving of the round dies and controlled to be driven.
Advantageous Effects of Invention
In the rolling machine and the method of rolling the gear using the rolling
machine according to the present invention, the turning angle on the inclined shaft (the A
shaft) turned around the push-in direction (the X axis), which is a direction in which the
2 0 round dies are pushed in, and the turning angle on the taper shaft (the B shaft) turned
around the Y axis can be adjusted by the control motor (a servo motor). Therefore, even
a non-skilled person can perform fine and highly accurate adjustment. The moving
headstock is guided by a plurality of guide rails having different heights. The guide rails
are disposed at an equal distance from a rolling center position (a power point position).
2 5 Therefore, it is possible to obtain the rolling machine having high rigidity during rolling.
30
The rolling machine can perform fine and highly accurate angle adjustment in the inclined
shaft (the A shaft) and the taper shaft (the B shaft). Therefore, the rolling machine is
suitable for correcting a helix of the gear.
Bl"ief Description of Drawings
Fig. 1 is an exterior view showing the exterior of an entire rolling machine.
7
Fig. 2 is an exterior view showing the exterior of a moving headstock during moving.
Fig. 3 is a diagram showing the exterior of a feed driving mechanism that drives the
moving headstock mounted with a round die in an X-axis direction.
Fig. 4 is a front view of the moving headstock viewed from a C direction in Fig. 2.
5 Fig. 5 is a partial sectional view showing a driving mechanism of inclined-shaft adjusting
means (an A shaft).
Fig. 6 is a plan view of the moving headstock mounted with the round die.
Fig. 7 is a front view of Fig. 6.
Fig. 8 is a sectional view of Fig. 6 taken along an A-A line.
10 Fig. 9 is a sectional view of Fig. 6 taken along a B-B line.
Fig. I 0 is a sectional view of Fig. 9 taken along a C-C line.
Fig. II is a sectional view of Fig. 9 taken along aD-D line.
Fig. 12 is a data diagram showing a relation between a tilt of a die main shaft and a tooth
trace of a gear.
15 Fig. 13 is an explanatory diagram of a configuration in which a die table is inclined by a
cam follower in another embodiment.
Fig. 14 is a modification of Fig. 13 and an explanatory diagram pmtially showing a
configuration in which the die table is inclined by an eccentric cam.
Fig. 15 is an explanatory diagram of a configuration in which driving of a motor is directly
2 0 connected to incline a die table in another embodiment.
Fig. 16 is an explanatory diagram of a configuration in which a die table is inclined via a
pinion gear in another embodiment.
Fig. 17 is a modification of Fig. 16 and an explanatory diagram of a configuration in
which the die table is inclined via a worm gear.
2 5 Fig. 18 is an explanatory diagram of a configuration in which a die table is inclined by
driving of two motors in another embodiment.
Fig. 19 is an explanatory diagram of a configuration in which a die table is inclined via a
taper-like wedge mechanism in another embodiment.
Fig. 20 is an explanatory diagram of a configuration in which a side surface of Fig. 19 is
3 0 shown in a sectional view.
Fig. 21 is an explm1atory diagram of a configuration in which two circular eccentric cams
are spaced apart and brought into contact with a die table and the die table is inclined
according to a rotating motion of the two circular eccentric cams in another embodiment.
8
Fig. 22 is an explanatory diagram showing the shape of the circular eccentric cams shown
in Fig. 21.
Fig. 23 is an explanatory diagram of a configuration in which two elliptical eccentric cams
are spaced apart and brought into contact with two die tables and the two die tables are
5 simultaneously inclined according to a rotating motion of the two elliptical eccentric cams
in the other embodiment.
Fig. 24 is an explanatory diagram showing the shape of the elliptical eccentric cams
shown in Fig. 23.
Fig. 25 shows a modification of a B-shaft swinging table and is a sectional view of a
10 configuration in which a turning angle of a B shaft is adjusted by an eccentric cam in
another embodiment.
Fig. 26 is an E-E sectional view of Fig. 25.
Description of Embodiments
A rolling machine I according to an embodiment of the present invention is
15 explained below with reference to the drawings. Fig. I is an exterior view showing the
exterior of the entire rolling machine I. Fig. 2 is an exterior view showing the exterior of
a moving headstock. Fig. 3 is a diagram showing the exterior of a feed driving
mechanism that drives the moving headstock in an X-axis direction. Fig. 4 is a front
view of the moving headstock viewed from a C direction in Fig. 2. As shown in Fig. I, a
2 0 round die 3, which is a tool for rolling, is mounted on a moving headstock 50 on a bed 2
set on a floor and made of a casting. A fixed headstock 5 is mounted and fixed on the
bed 2 to be opposed to the round die 3. On the fixed headstock 5, a round die 4 not
moving in the X-axis direction (a push-in direction, which is a direction in which the
round die 3 is pushed in) is mounted. In this example, a gear is rolled by two tools, that
2 5 is, the round die 3 and the round die 4.
Moving headstock 50
The round die 3 is mounted on the moving headstock 50. Two linear guide
rails 7 are fixedly disposed at an interval on the upper surface of the bed 2 (see Fig. 2). A
30 slider (a movable member) 10 incorporating a rolling member is fixedly disposed on the
lower surface of a lower frame 6, which configures the moving headstock 50. A linear
guide mechanism is configured by the linear guide rails 7 and the slider I 0. The lower
9
frame 6 is guided by the slider I 0 to be movable on the two linear guide rails 7. A
side-surface guiding section 53 is fixed on one side surface of the lower frame 6 integrally
with the side surface. An upper frame 51 is integrally provided and fixed in the
side-surface guiding section 53. Eventually, the lower frame 6, the side-surface guiding
5 section 53, and the upper fl-ame 51 configure a main body frame of the moving shaft table
50.
On the other hand, a rectangular sub-bed 8 is erected and disposed on a sideward
side of the upper surface of the bed 2. A lower part of the sub-bed 8 is fixed by bolts or
the like and provided integrally with the bed 2. The sub-bed 8 faces the side-surface
10 guiding section 53, which configures the moving headstock 50 on the lower frame 6. On
a side surface of the sub-bed 8, a linear guide rail 9 is disposed and fixed in parallel to the
linear guide rails 7 on the bed 2. A slider (a movable member) II is provided on a side
surface of the side-surface guiding section 53 and is guided by the linear guide rail 9
disposed on the sub-bed 8 to reciprocatingly move. A linear guide mechanism is
15 configured by the linear guide rail 9 and the slider 11. The moving headstock 50 is
guided by the two linear guide rails 7 disposed on the same plane and the one linear guide
rail 9 disposed on a surface perpendicular to the plane.
Eventually, the moving headstock 50 is guided by three sets of linear guide
mechanisms in total configured by the two linear guide rails 7 and the slider I 0 on the bed
2 0 2 and the one linear guide rail 9 and the slider II on the sub-bed 8. This means that the
moving headstock 50 is guided by two surfaces orthogonal to each other, and the moving
headstock 50 has high rigidity against a rolling pressure. According to the guide by these
linear guide mechanisms, the moving headstock 50 is capable of reciprocatingly moving
in the X-axis direction. As shown in Fig. 4, the linear guide rail 9 is disposed in a height
2 5 position different from the height position of the two linear guide rails 7. Therefore.
even if the rolling pressure acts on the moving headstock 50, since the linear guide rail 9 is
guided and supported at three points (lines), the linear guide rail 9 has a structure unlikely
to be deformed and therefore few rolling errors occur in the linear guide rail 9. That is,
the linear guide mechanisms are disposed in positions at an equal distance from a power
3 0 point (a rolling center position) in the X-axis direction at the time when rolling is
performed on a raw material by the round die 3 and the round die 4. The linear guide rail
9 and the two linear guide rails 7 are respectively disposed at an equal distance from the
power point position. Therefore, even if the moving headstock 50 receives the reaction
10
of the rolling pressure, the moments of the reaction have substantially the same magnitude
and thus there is an effect of reducing deformation.
Since the moving headstock 50 is guided at three points during the movement,
movement in the X-axis direction is also stable. Further, on an operation side of the
5 rolling machine I, a linear guide mechanism for reinforcement or guide for the moving
headstock 50 is absent. Therefore, there is no obstacle in carrying in/out a raw material
and the like. Fig. 3 is an exterior view showing a rear part of the moving headstock 50.
The moving headstock 50 receives a push-in force at the time of rolling. A ball nut 13 is
fixed on a back side of the moving headstock 50. The ball nut 13 is screwed into a screw
10 section of a ball screw (not shown in the figure). The center line of the ball nut 13 and
the ball screw is in the X-ax'is direction. The center line position of the ball screw
coincides or substantially coincides with the position of the power point. An X-axis
driving mechanism fixing table 14 is disposed at the rear end of the bed 2. The lower
end pmiion of the X-axis driving mechanism fixing table 14 is screwed to the rear end of
15 the bed 2. At the same time, a side surface of the X-axis driving mechanism fixing table
14 is fixed to the rear end of the sub-bed 8 by bolts or the like.
The bed 2, the sub-bed 8, and the X-axis driving mechanism fixing table 14 are
integral and configure a machine body, which is a main body of the rolling machine 1.
The machine body has high rigidity because the machine body forms a box shape with
2 0 three surfaces thereof opened. Since the upper surface and the front surface are opened,
the machine body does not hinder operation by an operator and does not hinder carrying-in
and carrying-out of a machining raw material. A transmission 15 incorporating a gear
transmission mechanism is disposed and mounted on the rear end face of the X-axis
driving mechanism fixing table 14. An output shaft of the transmission 15 is coupled to
2 5 the rear end of the ball screw. An input shaft of the transmission 15 is coupled to an
output shaft of the X-axis control driving motor 16. These transmission driving
mechanisms are publicly-known techniques and detailed explanation thereof is omitted.
When the X-axis control driving motor 16 is driven to rotate, the output shaft of the
transmission 15 drives the ball screw to rotate. When the ball screw is driven to rotate,
3 0 rotation in a rotating direction of the ball nut 13 screwed in the ball screw is regulated.
Therefore, the ball nut 13 is pushed or pulled in the X-axis direction. The moving
headstock 50 is guided by the two linear guide rails 7 and the one linear guide rail 9 to be
capable ofreciprocatingly moving in the X-axis direction.
11
The round die 3 is mounted on a round die table 21 disposed on the front surface
of the moving headstock 50. A rotation driving control motor 23 is mounted on a side
part of the round die table 21. A reduction gear (not shown in the figure) is coupled
between the rotation driving control motor 23 and a round die shaft 24. In this example,
5 the reduction gear is incorporated in the rotation driving control motor 23. The round die
shaft 24 is coupled to an output shaft of the reduction gear. The round die 3 is attached
to the round die shaft 24 and fixed by a key during rolling. Both ends of the round die
shaft 24 are rotatably supported on a bearing supporting table 25 and supported by a
bearing disposed on the inside of the bearing supporting table 25. The bearing
10 supporting table 25 is mounted and fixed on the round die table 21. Therefore, the round
die 3 is driven to rotate on the round die table 21 by the rotation driving control motor 23
and the built-in reduction gear.
15
Inclined-shaft adjusting means (A shaft) 30
The round die table 21 is capable of turning in the push-in direction (the X axis)
of the round die 3, that is, serving as an inclined shaft (an A shaft) shown in Fig. 4.
Therefore, the round die 3 on the round die table 21 is capable of turning in the inclined
shaft (the A shaft) on the lower frame 6 as shown in Fig. 4. Inclined-shaft adjusting
means (A shaft) 30 in this embodiment means angle adjusting means for adjusting, with
2 0 power according to control, a turning angle on the inclined shaft (the A shaft) turning
around the push-in direction (the X axis) of the round die 3. The structure of the
inclined-shaft adjusting means 30 is explained below. A shaft 63 is provided on the front
surface of a B-shaft swinging table 60 on the moving headstock 50 (see Fig. 8). A rear
part of the round die table 21 is attached to the shaft 63. The round die table 21 is
2 5 turnable around the shaft 63 (the A shaft).
Therefore, the rear surface of the round die table 21 slides to be turnable on a
turning sliding surface 65 on the front surface of the moving headstock 50. The turning
of the round die table 21 is driven by a desired angle amount by controlling an
inclined-shaft control motor 31 which is numerically rotation-angle-controllable (see Fig.
3 0 5). The inclined-shaft control motor 31 is mounted on the moving headstock 50. The
inclined-shaft control motor 31 performs, with a screw-feed driving mechanism driven by
the inclined-shaft control motor 31, turning driving on the inclined shaft (the A shaft) of
the round die table 21. The screw-feed driving mechanism is configured by a ball screw
12
that can accurately perform a feeding motion. Fig. 5 is a sectional view showing the
screw-feed driving mechanism of the inclined-shaft control motor 3 I. A timing pulley (a
toothed pulley) 32 is fixed to an output shaft of the inclined-shaft control motor 31. On
the other hand, a timing pulley (a toothed pulley) 34 is flxed to a ball-screw driving shaft
5 35 coupled to a ball screw 36. A timing belt (a toothed belt) 33 is laid over between the
timing pulley 32 and the timing pulley 34. The ball-screw driving shaft 35 is decelerated
via the reduction gear (not shown in the flgure ). The output shaft of the reduction gear
and the ball screw 36 are coupled by a coupling.
The ball screw 36 is rotatably supported by a bearing in a bearing bracket 37.
10 The distal end of the ball screw 36 is also rotatably supported by a bearing in a bearing
bracket 39. The bearing bracket 37 is flxed to the B-shaft swinging table 60 (see Fig. 8)
in the moving headstock 50 by bolts 38. The bearing bracket 39 is also supported by and
fixed to the -shaft swinging table 60 by bolts 40. A ball nut 4 I is screwed onto the ball
screw 36. A cam follower bracket 42 of the ball nut 4I is flxed by bolts 43. A cam
15 follower groove 44 is formed in the cam follower bracket 42. The direction of the
groove of the cam follower groove 44 is a Z-axis direction.
A cam follower 46 rotatably suppmied by a roller is inserted into the cam
follower groove 44. The cam follower 46 rolls in the cam follower groove 44 (the Z-axis
direction). A supporting shaft 47 of the cam follower 46 is fixed to the round die table
2 0 21 by a nut 48. As it is understood from the above explanation of the structure, the round
die table 2 I turns about the A shaft according to the rotation driving of the inclined-shaft
control motor 31. That is, when the inclined-shaft control motor 31 is driven to rotate,
the reduction gear, the timing pulley 32, the timing belt 33, the timing pulley 34, the
ball-screw driving shaft 35, and the ball screw 36 are driven. According to the rotation
2 5 of the ball screw 36, the ball nut 4I screwed in the ball screw 36 moves in the up-down
direction (the up-down direction in Fig. 5).
According to the up-down movement of the ball nut 4I, the cam follower groove
44 also moves up and down. The cam follower 46 inserted into the cam follower groove
44 is also driven to move in the up-down direction while slightly rolling in the cam
3 0 follower groove 44. The round die table 21 flxed to the cam follower 46 is turned in the
A shaft according to the up-down movement of the cam follower 46. As it is understood
from this explanation, the cam follower 46 can roll in the cam follower groove 44.
Therefore, a radial position of the cam follower 46, that is, a radial position centering on
13
the shaft 63 shown in Fig. 8 changes in the cam follower groove 44, whereby the round
die table 21 can perform a smooth turning motion about the shaft 63 on the B-shaft
swinging table 60.
5 Taper-shaft adjusting means (a B shaft) mounted on the moving headstock 50
Taper-shaft adjusting means (a B shaft) is angle adjusting means for adjusting a
turning angle about a taper shaft (a B shaft) turned around a Y axis orthogonal to the
push-in direction (the X-axis direction) of the round die 3 and orthogonal to the axis of a
raw material to be rolled. Details of the taper-shaft adjusting means are explained below.
10 Fig. 6 is a plan view of the moving headstock 50 viewed from above. Fig. 7 is a front
view of Fig. 6. Fig. 8 is a sectional view of Fig. 6 taken along an A-A line. The
moving headstock 50 is also a frame for receiving a push-in pressure from the ball screw
36, transmitting the push-in pressure to the round die 3, and turnably supporting the
B-shaft turning table 60. As explained above, the moving headstock 50 is generally
15 configured from the upper frame 5 I, the lower frame 6, and the side-surface guiding
section 53.
The upper frame 51 and the lower frame 6, which are tabular members, are
disposed vertically in parallel (in the vertical direction). The side-surface guiding section
53 that couples the upper frame 5 I and the lower frame 6 is disposed and fixed on side
2 0 surfaces of the upper frame 5 I and the lower frame 6. The slider I I provided in the
side-surface guiding section 53 is guided by the linear guide rail 9 disposed and fixed on
the sub-bed 8. A ball nut receiver 54 is fixedly disposed between the upper frame 5 I and
the lower frame 6. The ball nut receiver 54 is a member for receiving a push-in force in
the X-direction from the ball nut 41 and transmitting the push-in force to the upper frame
25 51 and the lower frame 6. Eventually, the upper frame 51, the lower frame 6. and the
ball nut receiver 54 are an integral structure.
The B-shaft swinging table 60 is disposed between the upper frame 5 I and the
lower frame 6 (see Fig. 7). The B-shaft swinging table 60 is a supporting table for
mounting the round die table 2 I and is a table for turning the round die table 2 I around the
3 0 B shaft. The B-shaft swinging table 60 is attached to be capable of turning about a shaft
6 I, that is, capable of turning in the moving headstock 50 about the B shaft. Therefore,
upper and lower parts of the shaft 61 are respectively rotatably supported on the upper
frame 51 and the lower frame 6 by a bearing 62 (see Fig. 8).
14
The shaft 63 explained above is rotatably supported on the front surface of the
B-shaft swinging table 60 by a bearing. The center line of the shaft 63 rotates around the
X axis. That is, the shaft 63 configures the A shaft. The center line of the shaft 63
substantially coincides with the center line of a ball screw that drives the X axis.
5 Therefore, a driving force of the ball screw can be directly transmitted to the round die 3
in the X-axis direction. A bearing 64 is provided at an end portion on the front surface of
the shaft 63. The bearing 64 is inserted into the rear surface of the round die table 21 and
supports turning of the A shaft in a turning direction of the X axis.
1 0 Driving mechanism 70 for the B shaft
A driving mechanism 70 for the B shaft is explained. Fig. 9 is a partial
sectional view of Fig. 6 taken along a B-B line. Fig. I 0 is a sectional view of Fig. 9
taken along a C-C line. Fig. I 0 is a sectional view of Fig. 9 taken along aD-D line. As
in the case of the A shaft, a numerically rotation-angle-controllable B-shaft control motor
15 71 is fixed and mounted on the upper surface of the upper frame 51 of the moving
headstock 50 via a reduction gear 74 and a motor bracket 71a. An output shaft of the
B-shaft control motor 71 is coupled to a driving B shaft 72 via the reduction gear 74 and
an eccentric ring. An upper part 75 of the shaft 72 is rotatably supported on the upper
frame 51 by a bearing 73. As shown in Fig. 10, an inserting section 75 at the upper end
20 ofthe driving B shaft 72 is coupled to an output shaft of the B-shaft control motor 71, the
reduction gear 74, and the eccentric ring.
On the other hand, as shown in Fig. 9 to Fig. II, a shaft portion 76 in the
position of the B-shaft swinging table 60 of the driving B shaft 72 is slightly eccentric
from the other portions (a large-diameter shaft portion of the driving B shaft 72, a shaft
2 5 p01tion 80 at the bottom end, etc.). A roller follower 77 is rotatably supported in the
outer circumference of the shaft portion 76. The roller follower 77 is disposed between
sliding members 78 of the B-shaft swinging table 60 (see Fig. II). The two sliding
members 78 are integrally provided in the B-shaft swinging table 60 and disposed to have
a parallel gap. The roller follower 77 is disposed in this gap. The roller follower 77 is
3 0 slidable in the gap. A shaft portion 79 in a lower part of the driving B shaft 72 is also
eccentric and slidably supported by the B-shaft swinging table 60 by the same supporting
structure. Further, a shaft portion 80 at the bottom end of the driving B shaft 72 is
rotatably supported by a bearing 81 in the lower fi·ame 6 of 50 the moving headstock 50.
15
5
''i
As it is understood from the structure explained above, when the driving B shaft 72 is
driven to rotate by the B-shaft control motor 71, the eccentric shaft portions 76 and 79
drive the B-shaft swinging table 60 and turn the B-shaft swinging table 60 about the shaft
61.
Driving mechanism for the .-ound die 4
The round die 4 is opposed to and symmetrically arranged with the round die 3.
Functions of rotation and turning of the round die 4 are substantially the same as the
functions of the round die 3. Explanation of the structure and the functions of the round
10 die 4 is omitted. However, the fixed headstock 5 mounted with the round die 4 is fixed
on the bed 2. The fixed headstock 5 in this embodiment does not move. During rolling,
the moving headstock 50 mounted with the round die 3 approaches the fixed headstock 5
to thereby perform the rolling. However, the fixed headstock 5 mounted with the round
die 4 may also be configured to be movable in the X -axis direction, and the fixed
15 headstock 5 and the moving headstock 50 mounted with the round die 3 may be caused to
approach each other during the rolling.
Work supplying/gripping mechanism 90
The rolling machine I includes, as shown in Fig. I, between the round die 4 and
20 the round die 3, a work supplying/gripping mechanism 90 for supplying a raw material to
be rolled and gripping the raw material during rolling. The work supplying/gripping
mechanism 90 is freely movable in the X-axis direction. That is, during the rolling, a
position in the X -axis direction is not controlled. The position of the work
supplying/gripping mechanism 90 is naturally specified by a rolling pressure in the X -axis
25 direction of the round die 4 and the round die 3. The work supplying/gripping mechanism
90 includes a numerically rotation-angle-controllable rotation control motor 91. The
rotation of the rotation control motor 91 is decelerated by a built-in reduction gear and
transmitted to a collet chuck 92 that grips a workpiece. The collet chuck 92 is capable of
releasing and gripping the workpiece by performing advancing and retracting movement
3 0 control by controlling a fluid cylinder 93. These mechanisms are not the gist of the present
invention and are publicly known. Therefore, details of the mechanisms are not explained.
In the case of a long workpiece, the center of the distal end of the workpiece is
supported by a center 95 of a tailstock. In rolling of a gear, rotation control of a
16
5
workpiece is often not performed. Therefore, the rotation control motor 91 docs not
drive to control the workpiece. Instead, both ends of the workpiece are gripped by both
the centers or the work piece is gripped by the collet chuck 92 and is not connected to an
output shaft of the rotation control motor 91.
Rolling of a gea1·
Rolling of a spur gear using sintered metal as a raw material by the rolling
machine I in this embodiment is explained. A tooth shape of a gear of a sintered alloy,
which is a sintered gear, is formed close to that of a final product. A plastic flow is
1 0 caused only in a surface layer close to a tooth surface to roll and mold the gear.
Therefore, rotation control of a work piece is not performed, and the workpiece freely
rotates. Rotation driving of the round die 3 and the round die 4 and the rotation of the
X -axis control driving motor 16 are simultaneously controlled. Rolling is performed
according to the control. A helix deviations of a machined gear is measured. As a
15 result, if a difference from a desired shape of the crowning is unacceptable, the
inclined-shaft adjusting means (the A shaft) 30 is actuated to perform necessary fine
adjustment. The inclined-shaft control motor 31 is driven to rotate and the round die
table 21 is turned in the A shaft to correct the crowing.
In the case of the helix deviations, similarly, the inclined-shaft control motor 31
2 0 is driven to rotate and the round die table 21 is turned in the A shaft to correct the helix
deviations. In the case of an error in which the helix is tapered, the B-shaft control motor
71 is driven and the B-shaft swinging table 60 is turned about the shaft 61 to correct the
round die 3 and the round die 4 in the B shaft. The configuration, in which an angle of
the helix of the gear to be machined is corrected by automatically changing the directions
2 5 of the dies of the A shaft and the B shaft by controlling to drive the control motor. has
been explained hereinabove.
Example of helix data
Fig. 12 is a diagram showing a state of a tooth surface of a gear rolled by the
3 0 rolling machine in this embodiment and showing an example of measured helix data.
The measured helix data is measured data indicating helix in the case in which machining
is performed by changing angles of the A shaft and the B shaft according to the directions
of the two die shafts. The angles of the A shaft and the B shaft are adjusted by a very
17
small amount. However, it has been proved that setting of a desired helix can be
performed at will by the rolling machine I explained above.
Other embodiments
5 It goes without saying that the configuration of the present invention is not
limited to the embodiment explained above and may be other configurations. A plurality
of examples are explained below concerning other embodiments. Since the A shaft and
the B shaft are common in that both the shafts change the directions of round dies 3 and 4
(hereinafter referred to as dies) and change angles of the. dies, the configuration applied to
10 the A shaft is explained below. Therefore, since this configuration can also be applied to
the B shaft, explanation of the B shaft is omitted.
All of configuration diagrams of figures referred to below are explanatory
diagrams shown as partial diagrams of a portion where an angle is changed. In the
explanation of the configuration, a suppmting structure to which the dies can be attached
15 to be turned is explained as a "die table" (in the embodiment explained above, equivalent
to the round die table) and a supporting structure that supports the die table on the fixed
side is explained as a "fixed table" (in the embodiment explained above, equivalent to the
B-shaft swinging table). Both of motors for driving are numerically
rotation-angle-controllable motors and are provided with reduction gears.
20
Another embodiment 1
Fig. 13 is a configuration example applied with a cam follower I 01. A motor
I 03 is attached to a fixed table 102. A reduction gear I 04 is coupled and attached to an
output shaft of the motor I 03. A ball screw 105 is rotated by driving of the motor I 03.
2 5 Both end pmtions of the ball screw I 05 are rotatably supported by bearings 1 06. A nut
body 1 07 meshes with the ball screw I 05. The nut body I 07 is movable in the axial
direction of the ball screw I 05 by being controlled by a very small amount. The cam
follower I 0 I is provided in the nut body I 07.
On the other hand, in the die table 108, a cam follower groove section I 09,
3 0 which is a groove formed in a forked shape, is provided. The cam follower 1 0 I is
inserted into and engaged with the cam follower groove section I 09. When the nut body
1 07 is driven by the motor I 03 and moves, the cam follower 10 I integral with the nut
body 107 drives the cam follower groove section I 09. Since the cam follower groove
18
section 1 09 is integral with the die table I 08, the movement of the cam follower groove
section I 09 is a swinging motion about an A point. According to the swinging motion,
the round die 3 is turned around the A point by a small angle in a direction indicated by an
arrow. The motor I 03 has a function of controlling a desired rotation angle according to
5 numerical control and performing rotation driving and rotates the ball screw 105 via the
reduction gear I 04.
In this way, a die II 0 can change a setting angle in a range of a small angle that
should be corrected according to the control by the motor 103. The die II 0 is adapted to
tooth trace correction machining of a gear according to the position change at the very
10 small angle. The configuration of this example is similar to the configuration of the
embodiment explained above. However, the configuration of this example is different
from the configuration explained above in that the cam follower I 0 I is integral with the
nut body I 07 side and the cam follower groove section I 09 is provided in the die table I 08.
The configuration of the embodiment partially shown in Fig. 14 is a modification in which
15 an eccentric cam 1 II is engaged with the cam follower groove section I 09 having the
same configuration. In the configuration of this case, an attachment position of the motor
112 is different and a ball screw is not provided. This is an example in which the
eccentric cam Ill is provided in an output shaft 113 of the motor I 03 via a reduction gear
(not shown in the figure). In this example, the die table 108 is swung as indicated by an
2 0 arrow in a range of an eccentric dimension of the eccentric cam Ill (a dimension
difference of a circumferential portion with respect to a rotation center).
Another embodiment 2
In this embodiment, as shown in Fig. 15, a die table 201 is directly connected to
2 5 a driving body and rotated. A motor 202 is provided in a fixed table 203 along an A axis
direction. A shaft end of the motor 202 is coupled to the die table 20 I via a reduction
gear mechanism 204. The motor 202 is numerically rotation-angle-controlled. The
motor 202 can rotate a die 205 by a small angle via the reduction gear mechanism 204
involving rotation of a very small amount set to low speed. This configuration is a
3 0 structurally simple configuration. However, since the motor 202 has to be attached on
the inside of a rolling machine, an attachment position is restricted.
19
Another embodiment 3
In this configuration, as shown in Fig. 16, a die table 301 is turned via a gear
mechanism. In this case as well, although not shown in the figure, a reduction gear is
coupled and attached to an output shaft of the motor 303. A pinion 304 is attached to a
5 shaft end of the motor 303 provided on a fixed table 302. The motor 303 is attached in a
ve1iical direction of the figure. In one die table 301, a gear 305 is fixed to be integral
with the die table 30 I or formed integrally with the die table 30 I. The gear 305 is a
sector gear having a shape including a teeth section in a part thereof. The teeth section
meshes with the pinion 304. The rotation center of the gear 305 coincides with an A
10 point of a die 306. Therefore, when the pinion 304 is rotated by a motor 303, which is
numerically rotation-angle-controlled, via a not-shown reduction gear mechanism, the
gear 305 also rotates and the die table 301 integral with the gear 305 swings about the A
point as indicated by an arrow by a small angle.
This gear mechanism may be a worm/worm wheel configuration shown in Fig.
15 17. A reduction gear 308 is coupled to an output shaft of a motor 307 provided on the
fixed table 302. A worm shaft 310 is coupled to an output shaft of the reduction gear 308.
Both ends of the worm shaft 310 are rotatably supported by bearings 309. A worm 311,
which is a driving gear, is integrated with or fixed to the worm shaft 310. On the other
hand, a worm wheel 312 is provided on the die table 301 integrally or as a separate
2 0 member. The worm wheel 312 meshes with the worm 311. Like the gear explained
above, the worm wheel 312 is a sector gear. The turning center of the worm wheel 312
coincides with the center A of the die 306. As explained above, the worm 311 is rotated
by the motor 307, which is numerically rotation-angle-controlled, via the reduction gear
308, the worm wheel 312 meshing with the worm 311 rotates according to the rotation of
2 5 the worm 311, and the die table 30 I is swung a small angle with the A point as a fulcrum
as indicated by an arrow.
Another embodiment 4
In this configuration, as shown in Fig. 18, a reduction gear mechanism 409 is
3 0 coupled to an output shaft of a motor 402, which is numerically rotation-angle-controlled.
Two motors 402, which can be independently controlled, are disposed on a fixed table 40 I.
A ball screw 403 is coupled to an output shaft of the motor 402. The ball screw 403 is
rotatably supported by a bearing 404. A nut body 405 is screwed into the ball screw 403.
20
A cam follower 406 is formed integrally with the nut body 405. The cam follower 406 is
movably inserted into a cam follower groove member 407. Therefore, when the nut body
405 is driven by driving of the motor 402, the cam follower 406 integral with the nut body
405 moves, and the cam follower 406 turns the die table 408 via the cam follower groove
5 member 407.
The nut body 405 moving in the axial direction meshes with the ball screw 403.
The cam follower 406 is fixed to the nut body 405. The cam follower 406 is movably
engaged with the cam follower groove member 407 integrally provided on the die table
408. In this configuration, two driving devices are disposed in parallel across an A point
10 of a die 410. In this configuration, when the die table 408 is swung by a small angle as
explained above, two motors 402 are synchronized and controlled to rotate in opposite
directions to each other, whereby angle control is performed.
Since the control of the two motors can be individually performed, different
kinds of control can be respectively performed for the two motors. Therefore, since play
15 (backlash) can be prevented, it is possible to prevent a slight shift of a helix due to
vibration or the like by maintaining a lock state. When the motors 402 are controlled to
rotate in the same direction, it is possible to forcibly shift the A point position of the die
410 (sec X in Fig. 18). This has a problem in design for enabling movement of the A
point but is possible in terms of a configuration.
2 0 Another embodiment 5
This configuration is a wedge structure as shown in Fig. 19 and Fig. 20. A ball
screw 504 rotating via a bearing 503 is directly connected to a motor 502, which can be
numerically rotation-angle-controlled, via a reduction gear 510 and supported on a fixed
table 50 I. A nut body 505 meshes with the ball screw 504 and is capable of moving in
2 5 an axial direction. A male engaging body 506 having a taper shape along a moving
direction of the nut body 505 is integrally fixed to the nut body 505. On the other hand,
on a die table 507, a taper-shaped female engaging body 508 engaging with the male
engaging body 506 and having a substantially T groove is provided.
The male engaging body 506 fits in the female engaging body 508 and is
3 0 capable of moving relative to each other along the taper shape via a slipping motion
according to mutual contact of taper parts 506a and 508a. The male engaging body 506
moves together with a motion of the nut body 505 according to the rotation of the motor
21
5
502. Since engaging sections are tapered, the female engaging body 508 moves back and
forth in a direction indicated by an arrow in a direction perpendicular to a moving
direction of the nut body 505. Consequently, the die table 507 integral with the female
engaging body 508 swings a small angle about a die A point as indicated by an arrow.
The engaging sections of the male engaging body 506 and the female engaging
body 508 have different moving forms, that is, one linearly moves and the other turns,
according to a positional shift in a taper direction. Therefore, according to a change in a
position in the taper direction, a positional shift in a turning direction simultaneously.
Relief for facilitating the movement .is required in design. The shape of the male
10 engaging body 506 in this example is a round shape in section. However, the male
engaging body 506 is not limited to this shape. Although not shown in the figure, in
order to ensure this wedge effect, this wedge device may be provided to be spaced apmt in
a symmetrical position across the A point. In this case, a pressing direction of the male
engaging body 506 against the female engaging body 508 is fixed to prevent backlash.
15 In this case, the configuration is performed only in the pressing direction, and is therefore
simplified.
Another embodiment 6
In this configuration, two eccentric cams 60 I are applied. A configuration
2 0 shown in Fig. 2 I is a structure in which two circular eccentric cams 60 I having the same
shape are linearly spaced apart and laid on top of the other like the shape shown in Fig. 22.
The two circular eccentric cams 60 I are disposed apart from each other at an equal
distance from an A point of a die 602 and are driven by a motor 603. A driving shaft 605
is coupled to an output shaft of the motor 603. The driving shaft 605 is rotatably
2 5 supported by bearings 604 disposed at both end portions of the driving shaft 605. The
two circular eccentric cams 601 are coupled by a driving shaft 605. A numerically
rotation-angle-controllable motor 603 is attached to a fixed table 606 via a reduction gear
607.
In the driving shaft 605 from the motor 603, the two circular eccentric cams 601
30 are provided to be spaced apmt from each other. The two circular eccentric cams 601
integrally rotate in the same direction. On the other hand, on a die table 608, a contact
surface 609 with which the two circular eccentric cams 601 are in contact is provided.
The two circular eccentric cams 601 are always in contact with the contact surface 609.
22
The two circular eccentric cams 601 are fixed to the driving shaft 605 with the directions
thereof shifted 180 degrees in the radial direction from each other.
In Fig. 21, a major axis section of the circular eccentric cam 60 I m an upper
position on the motor 603 side is in contact with the contact surface 609 of the die table
5 608. A minor axis section of the circular eccentric cam 60 I in a lower position is in
contact with the contact surface 609 of the die table 608. Therefore, as shown in the
figure, the die 602 turns by a difference S2-S I between the major axis section and the
minor axis section with the A point as a fulcrum and inclines a small angle. A die
position indicated by an alternate long and two short dashes line is a normal parallel
10 position. If a rotating position of the circular eccentric cam 60 I is reversed, the die 602
inclines a small angle in the opposite direction. Fig. 22 is an explanatory diagram
showing a configuration in a position where the shape of the circular eccentric cam is
shifted 180 degrees.
Fig. 23 is a diagram of a configuration corresponding to two die tables 701 a and
15 701 b. In the configuration, two cam members 703a and 703b arc disposed an equal
distance apart from each other in object positions between A points of two dies 702a and
702b. As shown in Fig. 24, the cam members 703a and 703b are cam members having
the same shape and are cam members having an elliptical shape to which major axis
sections and short axis sections are attached to be shifted from each other.
2 0 The cam members 703a and 703b having the same shape are disposed with the
positions thereof shifted 180 degrees. Like the fixed table explained above, a
numerically rotation-angle-controllable motor 705 is attached to a fixed table 704 via a
reduction gear 706. A driving shaft 707 from the motor 705 is rotatably supported by a
bearing 708. The two cam members 703a and 703b are fixed to be spaced apart with
2 5 directions thereof turned 180 degrees.
On the other hand, the die tables 70 I a and 70 I b have contact surfaces 709a and
709b with which the cam members 703a and 703b are respectively in contact. The die
tables 701a and 701b always maintain a contact state. According to the rotation of the
cam members 703a and 703b, the die tables 701a and 701b symmetrically swing and
3 0 incline. The configuration in Fig. 23 shows a state in which a major axis section of the
cam member 703b on the motor 705 side is in contact and a minor axis section of the cam
member 703a on an axis end side is in contact.
23
Therefore, the two dies 702a and 702b respectively incline a small angle in a
direction of an arrow with the A points as fulcrums with respect to parallel die positions
indicated by alternate long and two short dashes lines. In the inclination, as explained
above, a difference in the turning of the dies 702a and 702b is a difference S4-S3 between
5 the major axis sections and the minor axis sections. Fig. 24 is an explanatory diagram
showing a configuration in which the position of the shape of the elliptical eccentric cam
shown in Fig. 23 is shifted 180 degrees.
Another embodiment 7
A configuration 111 another embodiment 7 is a modification of the driving
1 0 mechanism of the B shaft shown in Fig. 9 to Fig. II. An example of the configuration is
shown in Fig. 25 and Fig. 26. Fig. 25 is a sectional view of the configuration. Fig. 26 is
an E-E sectional view of Fig. 25 and is a partial plan view corresponding to Fig. 6. A
B-shaft swinging table 80 I is held between the upper frame 51 and the lower claim 6.
The B-shaft swinging table 80 I is a supporting table on which the round die table 21
15 forming the configuration of the A shaft is mounted.
The B-shaft swinging table 80 I is provided to be capable of turning about the
shaft 61 (the B shaft). A shaft body 802 is rotatably provided piercing through the center
portion of the B-shaft swinging table 80 I. One end portion of the shaft body 802 is
coupled to the motor 71, which can be numerically rotation-angle-controlled, via a
2 0 reduction gear 75. Both end p01iions of the shaft body 802 are supported by a frame via
bearings 803. Two eccentric cams 804a and 804b are integrally fixed to both the end
portions of the shaft body 802 in the same configuration via keys 805. Since the
eccentric cams 804a and 804b involve wear, a material having high hardness compared
with the other members is used.
2 5 On the other hand, in the B-shaft swinging table 80 I, two contact members 806a
and 806b arc provided to be opposed to each other and to be opposed to the eccentric cams
804a and 804b. Like the eccentric cams 804a and 804b, the contact members 806a and
806b are formed of a material having high hardness that can withstand wear. Both of the
contact members 806a and 806b are fixed to the B-shaft swinging table 80 I by bolts, and
3 0 one contact member 806b is formed in a wedge configuration for performing interval
adjustment.
24
That is, as shown in the f1gure, one contact member 806b, which is a wedge
member, is inserted and pulled out in a direction of an arrow by a pushing and pulling
member 807, whereby the interval between the two contact members 806a and 806b is
adjusted according to the diameter of the circular eccentric cams 804a and 804b. When
5 the shaft body 802 is rotated a small angle by the motor 71 via the reduction gear 74, the
eccentric cams 804a and 804b change, while integrally rotating, eccentric positions
according to the rotation and press the contact members 806a and 806b.
According to the pressing, the B-shaft swinging table 80 I turns in a direction of
, an arrow with the B shaft as a fulcrum. According to the turning, it is possible to adjust
10 the B-shaft swinging table 80 I a small angle about the B shaft. In this example, liners
808 are provided on side surfaces of the contact members 806a and 806b to prevent a burr
involved in a relative motion from occurring. In this example, the two eccentric cams
804a and 804b are provided on both sides of the shaft body 802. However, one eccentric
cam may be provided in the center portion of the shaft body 802. In this example, since
15 such a configuration by the eccentric cams 804a and 804b is adopted, in the motions of the
eccentric cams 804 and 804b, stable turning without backlash can be performed. As a
result, it is possible to accurately perform control of a turning angle of the B shaft.
In this way, as a matter common to all the embodiments explained above, the
numerically rotation-angle-controllable motor is applied. Therefore, as change amounts
2 0 caused by associated motions involved in the rotation of the motor, all positions and
angles of the motor can be numerically grasped by calculation. Therefore, turning angles
of the A shaft and the B shaft can be automatically controlled at an accurately digitized
angle even if the turning angle is a small angle.
25
30
Reference Signs List
rolling machine
2
3
4
5
6
bed
round die
round die
fixed table
lower frame
25
7 linear guide
8 sub-bed
9 linear guide rail
14 X-axis driving mechanism fixing table
5 16 X-axis control driving motor
21 round die table
30 inclined-shaft adjusting means (A shaft)
31 inclined-shaft control motor
46 cam follower
10 50 moving headstock
51 upper frame 51
53 side-surface guiding section
60,801 B-shaft swinging tables
70 driving mechanism for the B shaft
15 71 B-shaft contro1motor
90 work supplying/gripping mechanism

CLAIMS
1. A rolling machine comprising:
a plurality of cylindrical round dies disposed centering on a raw material,
which is a workpiece, to roll the raw material fi·om an outer circumference of the raw
5 material;
die-rotation driving means for driving to rotate the round dies;
raw material supporting means for rotatably supporting the raw material; and
push-in means for bringing the round dies close to each other from the outer
circumference toward the raw material and pushing in the round dies while rotating
1 0 the round dies in the same direction in synchronization with each other,
the rolling machine further comprising:
a B-shaft swinging table that swings on a taper shaft (a B shaft) turning
around a Y axis orthogonal to a push-in direction (an X axis) of the round dies;
a die table that swings on an inclined shaft (an A shaft) turning around the
15 push-in direction (the X axis) of the round dies on the B-shaft swinging table;
20 2.
25
3.
taper-shaft adjusting means for adjusting a swing angle of the B-shaft
swinging table on the taper shaft (the B shaft); and
inclined-shaft adjusting means for adjusting a swing angle of the die table on
the inclined shaft (the A shaft).
The rolling machine according to claim 1, wherein
one of the round dies is mounted on a fixed headstock fixed on a bed,
the other of the round dies is mounted on a moving headstock that moves on
the bed, and
guiding means on the bed of the moving headstock is a plurality of linear
guide mechanisms (7, 7, 9) having different heights in a vertical direction.
The rolling machine according to claim I or 2, wherein the inclined-shaft adjusting
means and the taper-shaft adjusting means are means for correcting a tooth trace
and/ or a tooth shape of a gear.
27
4. The rolling machine according to claim 2, wherein the plurality of linear guide
mechanisms (7, 7, 9) are disposed at an equal distance from a position of a power
point in the push-in direction.
5. The rolling machine according to any one of claims I to 4, further comprising
5 work-rotation driving means for rotating the raw material in synchronization with a
rotation driving of the round dies to control driving of rotation of the raw material
around an axis of the raw material.
6. The rolling machine according to any one of claims I to 4, wherein the inclined-shaft
adjusting means and/or the taper-shaft adjusting means includes a screw shaft (I 05,
10 403) driven by a numerically rotation-angle-controllable motor (I 03) disposed on a
fixed side, and is configured to bring a cam member (101, 406), which operates
integrally with a moving object (107, 405) screwed into the screw shaft (105, 403)
and movable in an axial direction according to rotation of the screw shaft (105, 403),
into contact with the die table (I 08, 408) or the B-shaft swinging table (60) to
15 numerically adjust a direction of the round dies.
7. The rolling machine according to any one of claims I to 4, wherein the inclined-shaft
adjusting means and/or the taper-shaft adjusting means includes a shaft (76, 113,
802) driven to rotate by a numerically rotation-angle-controllable motor (71, 112)
disposed on a fixed side, and is configured to bring an eccentric cam member (77,
2 0 Ill, 804a, 804b), which operates according to a rotation driving of the shaft (76, 113,
802), into contact with a cam follower (78, 109, 806a, 806b) integral with the die
table (21) or the B-shaft swinging table (60, 801) to numerically adjust a direction of
the round dies.
8. The rolling machine according to any one of claims I to 4, wherein the inclined-shaft
2 5 adjusting means and/or the taper-shaft adjusting means includes gear transmission
means (304, 305, 311, 312) driven by a numerically rotation-angle-controllable
motor (303, 307) disposed on a fixed side, and is configured to rotate the die table
(301) or the B-shaft swinging table (60) according to a rotating motion of the gear
transmission means (304, 305, 311, 312) to numerically adjust a direction of the
3 0 round dies.
28
9. The rolling machine according to any one of claims 1 to 4, wherein the inclined-shaft
adjusting means and/or the taper-shaft adjusting means includes a screw shaft (504)
driven by a numerically rotation-angle-controllable motor (502) disposed on a fixed
side, includes a taper member (506, 508) screwed into the screw shaft (504) and
5 capable of advancing and retracting according to rotation of the screw shaft (504),
and is configured to press the die table (507) or the B-shaft swinging table (60)
according to a moving motion of the taper member (506, 508) to numerically adjust
a direction of the round dies.
I 0. The rolling machine according to any one of claims I to 4, wherein the inclined-shaft
10 adjusting means and/or the taper-shaft adjusting means includes a shaft (605, 707)
driven by a numerically rotation-angle-controllable motor (603, 705) disposed on a
fixed side, is provided with, in the shaft (605, 707), two eccentric members (601,
703a, 703b) coming into contact with the die table (608, 701a, 701b) and spaced
apart in an axial direction, and is configured to rotate the eccentric members (601,
15 703a, 703b) according to rotation of the shaft (605, 707) to change an eccentric
distance, and press the die table (608, 70la, 701 b) or the B-shaft swinging table (60)
to numerically adjust a direction of the round dies.
II. A method of rolling a gear by a rolling machine including:
a plurality of cylindrical round dies disposed centering on a raw material,
2 0 which is a workpiece, to roll the raw material from an outer circumference of the raw
material;
die-rotation driving means for driving to rotate the round dies;
raw material supporting means for rotatably supporting the raw material; and
push-in means for bringing the round dies close to each other toward the raw
2 5 material and pushing in the round dies while rotating the round dies in the same
direction in synchronization with each other,
the method comprising:
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adjusting, in order to correct a tooth trace and/or a tooth shape of the gear, a
turning angle on an inclined shaft (an A shaft) turned around a push-in direction (an
X axis) of the round dies; and
adjusting a turning angle on a taper shaft (a B shaft) turned around a Y axis
5 orthogonal to an axis of the raw material.
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12. The method of rolling a gear according to claim II, wherein the raw material is
rotated in synchronization with a rotation driving of the round dies and controlled to
be driven.