Patent Application
20170016707
A. Field of the Invention
This application addresses improvements to a precision three-roll gauge for the measurement of threaded fasteners. The thread gauge includes one gauge roll that is fixed and two gauge rolls that move to engage the threaded fastener. In one aspect of the invention, a pair of reverse sine bars controls the motion of the two movable gauge rolls in the reverse direction to allow the thread gauge to measure internal threads. In a second aspect of the invention, the thread gauge of the invention includes spring plungers to prevent the uncontrolled collision of parts of the thread gauge during use so that the gauge is quiet in operation and has a high-quality feel in the hands of the metrologist. In a third aspect of the invention, a wear indicator on the surface of thread rolls allows the metrologist to visually determine when the thread rolls reach the limits of permissible wear needed to maintain accuracy. Another aspect of the invention is a method of providing, using or certifying set plugs or ring gauges including evaluating those gauges to determine a ‘functional value’ considering all of the imperfections in the thread of the set plug or ring gauge.
B. Statement of the Related Art
U.S. Pat. No. 6,868,618 to Marcello Navarro issued Mar. 22, 2005 is hereby incorporated by reference as if set forth in full herein. Navarro '618 teaches a three-roll thread gauge in which one of the rolls is fixed and two of the rolls are movable. The fixed roll is fixed with respect to a base. The first movable roll is attached to and moves with a first table. The second movable roll is attached to and moves with a second table. The first and second tables engage a carriage that features a cross-slide by which the first and second tables may advance or retreat together in a longitudinal direction with respect to the base either toward or away from the fixed roll. The first and second carriages may move with respect to the cross-slide of the carriage in a lateral direction toward or away from each other.
When the carriage is advanced toward the fixed gauge roll, the motion of the first movable thread roll is constrained in the lateral direction by a first sine bar fixed to the base and by a mating first adjustable strip attached to the first table. The first sine bar and first adjustable strip define an angle with respect to the longitudinal direction. The second sine bar and second table for the second movable gauge roll are a mirror image of the first sine bar and first table and operate in the same fashion.
In use, a male threaded object is placed in the space between the three gauge rolls. The carriage is advanced toward the fixed gauge roll. The first adjustable strip of the first table contacts the bearing surface of the first sine bar. The second adjustable strip of the second table contacts the bearing surface of the second sine bar. The adjustable strips and bearing surfaces, which are precision surfaces, are in sliding contact as the two movable gauge rolls advance toward the fixed gauge roll.
When the first and second adjustable strips are in contact with the bearing surfaces of the first and second sine bars, the three gauge rolls in combination define a triangle. The included angles of the triangle are equal for every position of the three gauge rolls, which is an advantage of the Navarro '618 gauge over the prior art because it allows the three-roll gauge to measure male threaded objects of different diameters without re-calibration. The Navarro '618 gauge allows measurement of external threads but does not measure internal threads.
When a metrologist is advancing the carriage toward the fixed gauge roll, the bearing surfaces of the first and second sine bars and the adjustable strips will collide. The surfaces of the carriage that engage the first and second tables also will collide with the corresponding surfaces of the tables both when the carriage is advanced toward the fixed gauge roll and when the carriage is withdrawn from the fixed gauge roll. The collisions may make a sound and a mechanical vibration that the metrologist may find less-than-desirable. If the metrologist is advancing or retracting the carriage manually, the metrologist may feel the impacts. Also, the sliding contact between the bearing surfaces and the adjustable strips may cause wear on the adjustable strips or bearing surface.
For precision measurement, tool wear will bias the measurements. Being able to detect when a maximum allowable wear has occurred will save time and money for the owner and operator of the measurement tool.
Users and manufacturers of threaded fasteners can readily determine the ‘pitch diameter’ of the threaded fasteners using conventional techniques. They can compare, both directly and statistically, the ‘pitch diameter’ of different fasteners measured at different times, by different metrologists, using different equipment and at different locations. The ‘pitch diameter’ does not determine whether two threaded fasteners will successfully mate and does not measure the accuracy of the threads of a fastener. Because of a lack of common language and common standards, the users and manufacturers of threaded fasteners are not readily able to directly and statistically compare the overall accuracy of the threaded fasteners and are not able to compare whether and to what extent the threaded fasteners will successfully mate with other threaded fasteners, particularly where the measurements are of different fasteners or by different metrologists or using different equipment or at different locations.
A. Reverse Sine Bar
The precision thread gauge has one stationary gauge roll and two movable gauge rolls. The thread gauge features a carriage configured to move along a longitudinal axis toward and away from the fixed gauge roll. The movable gauge rolls are attached to a first and a second table. The first and second table are moved by the carriage in the longitudinal direction and also are configured to move in the lateral direction with respect to the carriage.
The precision thread gauge is equipped with a first and a second reverse sine bar. The first reverse sine bar constrains the motion of the first table in the lateral direction when the carriage is moved in the longitudinal direction away from the fixed gauge roll. The second reverse sine bar is a mirror image of the first reverse sine bar. The first and second reverse sine bars cause the fixed gauge roll, the first gauge roll and the second gauge roll to define a triangle with constant included angles as the carriage is moved away from the fixed gauge roll. As a result, the precision thread gauge may be used to measure an internal thread, such as the internal thread of a ring gauge.
The precision thread gauge may have both sine bars and reverse sine bars, to allow both external and internal threads to be measured.
B. Spring-Loaded Contact Balls.
One or more spring-loaded contact balls are provided to cushion the impacts of the surfaces of the first and second tables and the corresponding surfaces of the carriage of the thread gauge. Spring-loaded contact balls also may be used to cushion the impacts of the sine bars or reverse sine bars and the corresponding surfaces of the first and second tables. The spring-loaded contact balls also may roll, resulting in a rolling engagement rather than a sliding engagement between the contacting surfaces, reducing wear of those surfaces. The spring and contact ball assembly may be installed on either of the colliding surfaces and the contact ball is proud of the surface to which it is installed.
When the carriage advances toward the fixed gauge roll, the contact ball at the interface between the carriage and the first table touches the opposing surface before the opposing surfaces of the carriage and first and second tables touch. The spring rate of the springs loading the contact balls is selected to cushion the impact between the surfaces, which reduces noise from that impact and imparts a high-quality feel to the gauge, improving the aesthetic experience of using the gauge.
Spring-loaded contact balls also may be installed at the interface between the first and second sine bars or the first and second reverse sine bars and the corresponding surfaces of the first and second tables. The spring rate of the spring loading the contact balls also is selected so that the force required to compress the spring so that corresponding surfaces touch is greater than the force required to move the table in the lateral direction. In use, the bearing surface and the adjustable strip are separated by the contact ball as the table is advancing toward the fixed gauge roll, or, for a thread gauge equipped with reverse sine bars, as the table retreats from the fixed gauge roll. The contact balls roll in response to the relative motion of the contact ball and the opposing surface. When the movable gauge rolls touch the object to be measured, motion of the tables with respect to the fixed roll ceases and an increase in force applied to the carriage overcomes the force of the spring and pushes the adjustable strip against the bearing surface.
The result is a rolling contact and not a sliding contact between the corresponding surfaces until the movable gauge rolls contact the object to be measured. The rolling contact results in less wear and fewer adjustments to the gauge.
C. Gauge Roll Wear Indicator
The rolls gauges may be provided with an indicator layer of a contrasting color to the underlying substrate. For example, the gauge roll may be manufactured to be the minimum diameter that will achieve acceptable measurement accuracy for the gauge. The gauge roll then may be coated with a wear indicator of a contrasting color, for example titanium nitride, titanium carbon nitride or titanium aluminum nitride. Titanium nitride can offer a wear layer of a gold color, while titanium carbon nitride and titanium aluminum nitride can offer colors ranging from gray to black.
The wear indicator may coat the gauge roll by chemical vapor deposition or physical vapor deposition, vacuum deposition, sputtering deposition, thin-film deposition, dip-coating, painting, plating, anodizing or by any other coating technology suitable for the substrate from which the structure of the gauge roll is composed and for the coating. The gauge roll may be coated with multiple contrasting layers. The final dimensions of the completed gauge rolls are selected so that the gauge roll can be used to make adequately accurate measurements.
In use, the metrologist will observe the surface of the gauge rolls at the location where the gauge rolls contact the object to be measured. If the metrologist observes no change in color of the gauge roll at that location, then the metrologist can conclude that the gauge roll is not so worn as to prevent accurate measurement. If the metrologist observes the contrasting color of the substrate or of another layer on which the wear layer is deposited, then the metrologist will conclude that the gauge roll has worn. If the metrologist observes the color indicating that the gauge roll has worn to the acceptable limits, then the metrologist will conclude that the thread gauge needs maintenance.
The gauge roll may be manufactured with a number of reference locations on the gauge roll that will produce accurate measurements. The reference locations may be demarcated by the structure of the gauge roll, as by grooves or fillets in the surface of the gauge roll, or by the color of the reference portions, or by keys or other shapes limiting the mounting options for the gauge roll or by indicia marked on the gauge roll.
When the metrologist determines that a location on the gauge roll is worn and requires service, the metrologist may loosen the fastener attaching the gauge roll to the gauge and rotate the gauge roll to expose an un-worn reference location on the gauge roll. If all of the wear locations on the gauge roll are worn, the metrologist will remove and replace the gauge roll. The metrologist will tighten the fastener holding the gauge roll in place. The gauge is then ready for further measurement.
D. Method and System of Functional Value Measurement
The invention is also a method and system of providing set plugs or ring gauges certified with a functional value of the set plug or ring gauge. The set plug or ring gauges may be marked with the functional value. The invention is also a method of checking and inspecting threaded fasteners using set plug or ring gauges certified or marked with a functional value.
Any manufacturer of objects that are held together by threaded fasteners likely inspects those threaded fasteners to determine whether to accept or to reject the fasteners. Any manufacturer of threaded fasteners also inspects its products to monitor the production process and to detect and predict, for example, worn tooling interfering with production quality. In any inspection of a male threaded fastener of a given lead, thread profile and straightness, there are two considerations: (1) that the male threaded fastener is adequately large so that the fastener is strong enough not to fail in service, and (2) that the male threaded fastener is adequately small so that the male threaded fastener will fit in a corresponding female threaded fastener.
The ‘pitch diameter’ is a measurement of the diameter of an imaginary cylinder at which the length of the thread and of the groove between adjacent threads in the longitudinal direction is equal. The ‘pitch diameter’ therefore is an indication of how much metal or other solid material is in a threaded fastener and thus whether the threaded fastener is adequately strong to avoid failure of the fastener in service.
The pitch diameter is measured at three points on the fastener—with two points on one side and one point opposite the other two, and does not measure the thread as a whole. The pitch diameter measurement ignores any imperfections in the thread. Since every threaded fastener has imperfections, the ‘pitch diameter’ represents the lower limit of the size of a male fastener. If the pitch diameter of a male threaded fastener is too small, the male threaded fastener may be able to mate with the corresponding female threaded fastener, but the male threaded fastener or the thread connection or both will be weak and may fail in service. The above discussion applies equally to female threaded fasteners, but in reverse. For a female threaded fastener, the ‘pitch diameter’ measures the theoretical maximum size of the opening in the fastener.
The ‘functional value’ of a fastener is the effective diameter of the overall threaded portion of the fastener, including all defects in the threads. The ‘functional value’ is a measure of whether one threaded fastener will actually be able to mate with another threaded fastener. Because every thread has defects, the ‘functional value’ of a male threaded fastener is always larger than the ‘pitch diameter.’ The ‘functional value’ of a female threaded fastener is always smaller than the ‘pitch diameter’ of the female threaded fastener. The closer the measured ‘functional value’ to the ‘pitch diameter,’ the fewer the defects in the thread and hence the more accurate the thread. In general, an accurate thread will be easier to assemble and disassemble and stronger in service than an inaccurate thread. If the functional value of a male threaded fastener is too large and the functional value of a female threaded fastener too small, then the threaded fasteners will not mate at all. Set plugs and ring gauges used to calibrate other thread gauges are calibrated and marked for pitch diameter and are not calibrated or marked for ‘functional value.’
The Navarro '618 gauge or the improved gauge described above and equipped with full thread gauge rolls indicates the ‘functional value’ of the plug or ring gauges, which aggregates all of the errors of the thread to be measured. The ‘functional value’ of a set plug accurately indicates whether the female thread measured by the set plug will effectively mate with a male thread having a consistent ‘functional value.’
For the method of the invention, a gauge user may provide a set plug or ring gauge to a gauge service provider. The gauge service provider will measure the set plug or ring gauge with the Navarro '618 gauge, with the improved gauge addressed above, or with another gauge that measures the functional diameter of the set plug or ring gauge. The measurement obtained is the functional value of the set plug or ring gauge. The service provider will provide a certificate certifying the measured functional value of the set plug or ring gauge. Optionally, the service provider may mark the set plug or ring gauge with the measured functional value.
In use, the user of the set plug or ring gauge may calibrate another thread gauge, such as the Navarro '618 gauge, a tri-roll gauge, or other suitable gauge using the certified or marked set plug or ring gauge. The calibrated thread gauge is then configured to measure the functional value of a threaded fastener. To inspect a threaded fastener, the user will measure the pitch diameter of the thread in the conventional manner and will measure the functional diameter of the thread using the gauge that has been calibrated to measure functional value. By comparing the measured pitch diameter and functional value, the user can measure a degree of defectiveness and hence measure the accuracy of the threaded fastener.
Because the functional value thread gauges are calibrated to a common reference standard, the user can compare, both directly and statistically, the measured functional values and the accuracy of the threaded fastener to other measurements of functional value and accuracy, including measurements made by other persons, at other times, at other locations, on other equipment, and testing other threaded fasteners. The user of the thread fastener, the manufacturer of the threaded fastener, testing laboratories, standards setting bodies, and anyone else to whom threaded fasteners are important can use the common language and common measurement to determine whether threaded fasteners will fit together and how accurate the threads of the threaded fasteners are.
In the absence of the Invention; that is, without common, repeatable functional value testing, the user and manufacturer of the threaded fastener or other interested party cannot perform reliable direct or statistical evaluations of the fasteners. The result is partial blindness and lack of process control on the part of the user of the threaded fastener and the manufacturer of the threaded fastener—they are less able to detect approaching failure, say, due to worn tooling, before that failure occurs.
A first table 24 is supported by the base 6. The first table is configured to move with respect to the base 6 in the first direction 26, both toward and away from the fixed gauge roll 8. The first table 24 defines a first table advancing contact surface 28 that engages the carriage first advancing contact surface 16 when the carriage 10 moves toward the fixed gauge roll 8. The first table 24 defines a first table retreating carriage contact surface 30 that engages the carriage first retreating contact surface 20 when the carriage is moving away from the fixed gauge roll 8.
When the carriage 10 is advancing toward the fixed gauge roll 8, the engagement between the first table advancing contact surface 28 and the carriage first advancing contact surface 16 causes the first table 24 also to move in the longitudinal direction 12. The motion of the first table 24 is constrained laterally when the first table 24 is advancing by the first sine bar 32. The first sine bar contact surface 34 engages the first table 24 when the carriage 10 and the first table 24 are advancing, forcing the first table 24 to move laterally with respect to the longitudinal axis 12 as the first table 24 advances. The first movable gauge roll 36 is attached to the first table 24 and moves with the first table 24.
When the carriage 10 moves in the longitudinal direction 12 away from the fixed gauge roll 8, the carriage first retreating contact surface 20 engages the first table retreating contact surface 30, forcing the first table 24 also to move in the longitudinal direction 12. When retreating from the fixed gauge roll 8, the lateral motion of the first table 24 is constrained by the first reverse sine bar 38. The first reverse sine bar contact surface 40 contacts the first table 24, forcing the first table 24 to move laterally as the first table 24 retreats in the longitudinal direction 12 away from the fixed gauge roll 12.
The second table 42 is a mirror image of the first table 24 and the second table 42 moves in a manner identical to the first table 24. When the carriage 10 is advancing toward the fixed gauge roll 8, the engagement between the second table advancing contact surface 44 and the carriage second advancing contact surface 20 causes the second table 26 also to move in longitudinal direction 12. The motion of the second table 42 is constrained laterally when the second table 42 is advancing by the second sine bar 48. The second sine bar contact surface 50 engages the second table 42 when the carriage 10 and the second table 42 are advancing, forcing the second table 42 to move laterally with respect to the longitudinal axis 12 as the second table 42 advances. The second movable gauge roll 52 is attached to the second table 42 and moves with the second table 42.
When the carriage 10 is moving in the longitudinal direction 12 away from the fixed gauge roll 8, the carriage second retreating contact surface 22 engages the second table retreating contact surface 46, forcing the second table 42 also to move in the longitudinal direction 12. When retreating from the fixed gauge roll 8, the lateral motion of the second table 42 is constrained by the second reverse sine bar 54. The second reverse sine bar contact surface 56 contacts the second table 42, forcing the second table 42 to move laterally as the second table 42 retreats in the longitudinal direction 12 away from the fixed gauge roll 12.
In use, and as shown by
The gauge 2 may dispense with the first and second sine bars 32, 48 while retaining the first and second reverse sine bars 38, 54, in which event the gauge 2 is suitable for measurement only of female threads, such as a ring gauge.
The spring-loaded contact balls 62 provide a perception of high-quality to the metrologist because the spring-loaded contact balls extend beyond the surface to which the contact ball 62 is inset, cushioning the blow when one contact surface collides with another and reducing any sound caused by the impact.
The possible orientations of the gauge roll 8, 36, 52 on the gauge 2 may be limited by the physical characteristics of the gauge roll 8, 36, 52 and of the mounting location for the gauge roll 8, 36, 52 or both. For example, the mounting location may include one or more upright pins that engage slots 72 and, in the example of
As shown by
This non-provisional patent application is entitled to priority from provisional application No. 62/192,307, by inventor Marcello Navarro, filed Jul. 14, 2015.
| Number | Date | Country | |
|---|---|---|---|
| 62192307 | Jul 2015 | US |
