# Patent

## Title
Swaging feedback control method and apparatus

## Abstract

A swaging system includes a swaging assembly, a sensor, and a controller. The swaging assembly includes a movable tool, the movable tool operate to exert force on a die. The die is configured to reduce a dimension of a work piece responsive to the exerted force, the dimension reduction having a relationship to a stroke of the movable tool. The sensor is operable to obtain information including a measurement of the reduced dimension of the work piece. The sensor is operable to generate a measurement signal representative of the obtained information. The controller is operably coupled to receive the measurement signal from the sensor, and is operable to cause adjustment the stroke of the movable tool responsive to the measurement signal.

## Background
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/282,268, filed Apr. 6, 2001, which is incorporated herein by reference.


FIELD OF THE INVENTION
The present invention relates generally to the field of machine tools, and more particularly, to the field of tools that operate to reduce the size or diameter of a work piece, or swaging tools.
BACKGROUND OF THE INVENTION
Swaging is a method that is employed to reduce the diameter or thickness of a rod-like or tube-like structure. Swaging may be carried out by forging, squeezing or hammering the work piece. In one type of swaging tool, the work piece is fed into an opening formed by a plurality of die segments arranged generally surrounding the opening. The die segments are forced radially inward to a predetermined point. As the die segments travel radially inward, they converge on the work piece and strike the outer diameter of the work piece, thereby tending to reduce the diameter of the work piece. To force the die segments inward, a movable tool assembly often engages the outside of the die segments to push them radially inward.
After the swaging operation, the die segments are in a compressed state, substantially surrounding the work piece. To remove the work piece, the die segments must be moved radially backward to an non-compressed or expanded state. Once the die segments are in their normal expanded state, the work piece may be removed and another work piece may be inserted. The process may then be repeated.
In some cases, the swaging mechanism is used on portions of a continuous work piece such as a long continuous tube or pipe. In such cases, the swaging mechanism may operate in a substantially similar manner as described above, except that when the swaging die segments move to the expanded state after swaging one portion of the continuous work piece, the work piece is simply advanced to place an adjacent portion of the work piece in position to be swaged.
In general, one desired result of the swaging process is to produce work pieces having a predetermined thickness, diameter or other dimension. As portions of the swaging tool experience wear, however, there is a potential for variations in the diameter or other dimension of the swaged work piece. For example, when the die segments wear and get smaller, they reduce the outer dimension of the work piece to a commensurate lesser degree.
Such variations in result may be reduced or eliminated by replacing the worn parts, including, but not limited to, the die segments. However, frequent tool repairs and part replacement can be costly and time consuming. Accordingly, there is an economic incentive to reduce the frequency of tool repair and replacement. Nevertheless, infrequent tool repairs and part replacement can undesirably increase the error margin in the dimensions of the final swaged product.
What is needed, therefore, is a swaging assembly that can produce parts of a predetermined thickness while reducing the need for frequent repair and part replacement.
SUMMARY OF THE INVENTION
The present invention addresses the above needs, as well as others, by providing a swaging feedback control method and apparatus that detects the dimension of a swaged work piece and then adjusts the stroke of the movable tool of the swaging device to compensate for any variation in dimension from an desired size. As a result of the adjustment, the dimension of the next swaged work piece should have a reduced variation from the desired.
A first embodiment of the invention is a swaging system that includes a swaging assembly, a sensor, and a controller. The swaging assembly includes a movable tool, the movable tool operate to exert force on a die. The die is configured to reduce a dimension of a work piece responsive to the exerted force, the dimension reduction having a relationship to a stroke of the movable tool. The sensor is operable to obtain information including a measurement of the reduced dimension of the work piece. The sensor is operable to generate a measurement signal representative of the obtained information. The controller is operably coupled to receive the measurement signal from the sensor, and is operable to cause adjustment the stroke of the movable tool responsive to the measurement signal.
Thus, the above described embodiment is operable to cause adjustment of the stroke of a movable tool in response to a measurement of the measurement of the previously swaged work piece. The stroke adjustment typically results in at least some adjustment to the reduced dimension of the next work piece. Such a method thereby automatically regulates at least one aspect of the swaging operation.
Another embodiment of the invention is a method of performing a swaging operation on a plurality of work pieces. The method includes employing a swaging assembly to reduce a dimension of a first work piece, the dimension of the first work piece having a first value. The method further includes obtaining information regarding a measurement of the dimension of the first work piece. The method also includes employing the swaging assembly to reduce a dimension of a second work piece, the dimension of the second work piece having a second value, a difference between the first value and the second value based at least in part on the obtained information.
Thus, the above embodiment swages a subsequent work piece based in part on measurements of the first work piece. Both of the above described embodiments can produce parts having consistent dimensions despite wear on the swaging tool and the associated die. For example, as the die wears, which otherwise causes error in the swaging operation, the swaging stroke is merely increased to compensate for the die wear, thereby producing consistent swaging workpieces throughout much or all of the useful life of the die.
The above-described features and advantages, as well as others, will become more readily apparent to those of ordinary skill in the art by reference to the following detailed description and the accompanying drawings.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an exemplary embodiment of a swaging feedback control system 200 according to the present invention;
FIG. 2 shows a perspective view of an exemplary swaging assembly 10 that includes an exemplary embodiment of a die assembly 12 according to the present invention;
FIG. 3 shows a partially exploded perspective view of a lower portion of the swaging tool of the swaging assembly of FIG. 2;
FIG. 4 shows a partially exploded perspective view of an upper portion of the swaging tool of the swaging assembly of FIG. 2;
FIG. 5 shows a different partially exploded perspective view of a lower portion the swaging tool of the swaging assembly of FIG. 2;
FIG. 6a shows a fragmentary perspective view of an exemplary embodiment of a swaging die assembly according to the present invention;
FIG. 6b shows a cross sectional view of the swaging die assembly of FIG. 6a; 
FIG. 7 shows an exploded perspective view of several elements of the swaging tool and the die assembly of FIGS. 2 and 6a; 
FIG. 8 shows a fragmentary cutaway portion of the swaging assembly of FIG. 2 wherein the movable tool is in the rest position;
FIG. 9 shows a fragmentary cutaway portion of the swaging assembly of FIG. 2 wherein the movable tool is in the swaging position; and
FIG. 10 shows an exemplary flow diagram of steps performed in carrying out a method according to the invention.



DETAILED DESCRIPTION
FIG. 1 shows an exemplary embodiment of a swaging feedback control system 200 according to the present invention. The swaging feedback control system 200 includes a swaging assembly 202, a sensor assembly 204, a controller 206, and a transport mechanism 208.
The swaging assembly 202 includes a movable tool 210, a drive control mechanism 212, and a die or contact element 214. The movable tool 210 is configured to exert force on the die 214 under the control of the drive control mechanism 212. To this end, the movable tool 210 may comprise a hydraulic cylinder having a controllable stroke length. However, it will be appreciated that other drive mechanisms may be used, preferably those with controllable stroke lengths. The drive control mechanism 212 is operable to control the operation of the movable tool responsive to signals received from the controller 206. For example, the drive control mechanism 212 may be a servo controller device, as is known in the art.
The die 214 is configured to contact a work piece, not shown, in order to reduce a dimension of the work piece responsive to the exerted force. The die 214 is cooperatively arranged with the movable tool such that variation in the stroke length of the movable tool 210 causes variation in the reduction of the dimension of the work piece. For example, the die 214 may include plural segments that surround and encase at least a portion of the work piece. In such a case, the stroke of the movable tool 210 cause the plural segments of the die 214 to converge around and engage the work piece, with the resulting force reducing the outer diameter of the work piece. If the stroke length is increased, then the plural segments of the die 214 may converge even further into the work piece, with the resulting force reducing the diameter of the work piece to a greater extent. Such swaging die elements are known and can take many forms.
FIG. 2, discussed further below, shows in additional detail an exemplary swaging assembly 10 that may be employed as the swaging assembly 202 of FIG. 1. The plural die segments 30a, 30b and so forth of the swaging assembly 10 are shown by way of example in FIG. 6a, also discussed below.
Referring again to the embodiment of FIG. 1, the sensor assembly 204 is a device that is operable to obtain information including a measurement of a dimension of a work piece, for example, its outer diameter. The sensor assembly 204 is further operable to generate a measurement signal representative of the obtained information. To this end, the sensor assembly 204 may include a measuring device such as a laser, machine vision, or other video-based measurement device, as well as a fixturing mechanism designed to orient the work piece to be measured in a predefined position suitable for taking measurements. Suitable sensor assemblies are well known, and the details of such an assembly would be known to one of ordinary skill in the art.
The controller 206 may suitably be one or more processors, microcontrollers, microprocessors, programmable logic circuits or similar programmable devices, as well as support circuitry associated therewith. The controller 206 is operably coupled to receive measurement signals from the sensor assembly 204. In an exemplary embodiment, the controller 206 is connected to the sensor assembly 204 through an RS-232 communication link.
The controller 206 is further operable to cause adjustment the force exerted by (i.e. the stroke of) the movable tool 210 responsive to the measurement signal received from the sensor assembly 204. To this end, the controller 206 provides control signals to the drive control mechanism 212 that defines the stroke. In the exemplary embodiment described herein, the controller 206 is connected to the drive control mechanism 212 via an RS-232 communication link.
The transport mechanism 208 may be any suitable automated system that can move workpieces from one processing station to another, including but not limited to a robotic system or a pick and place mechanism, both of which are well known in the art.
A flow diagram illustrating an exemplary operation of the swaging assembly 202 is shown in FIG. 10. In particular, in step 252, the next work piece is placed into the swaging assembly 202. To this end, the transport mechanism 208 or another similar transport mechanism may manipulate the work piece into position. Once the work piece is in place, the swaging assembly 202 performs step 254.
In step 254, the swaging assembly 202 operates to reduce a select dimension of a first work piece. To this end, the controller 206 will have previously provided (upon start-up, via manual manipulation, or through operation of step 262, discussed below) control signals to the drive control mechanism 212 that contain information relating to a select stroke length of the movable tool 210. As discussed above, the stroke length defines, at least in part, the reduction in the dimension of the work piece that is accomplished in the swaging process. Thus, the select stroke length is one that ideally corresponds to the desired dimension reduction in the work piece.
The drive control mechanism 212 then, in accordance with the information relating the select stroke length received in the control signals, causes the movable tool 210 to execute its stroke. As the movable tool 210 executes its stroke, the die 214 reduces the dimension of the work piece.
Thereafter, in step 256, the transport mechanism 208 moves the swaged work piece to the sensor assembly 204. In step 258, the sensor assembly 204 obtains information regarding a measurement of the dimension of the work piece. For example, the sensor assembly 204 may generate a measurement of the outer diameter of the work piece. The sensor 204 communicates the measurement information to the controller 206.
It will be appreciated that in some embodiments, the sensor assembly 204 may be configured to obtain the measurement information while the work piece is still fixtured in the swaging assembly 202.
In any event, after step 258, the controller 206 performs step 260. In step 260, the controller 206 determines whether the measured dimension of the work piece is within tolerance. To this end, the controller 260 may suitably compare the measurement information with an ideal value and determine whether the difference exceeds a predetermined threshold. Regardless of how it is determined whether the reduced dimension is within tolearance, the controller 206 proceeds to step 262 if the measured dimension is not in tolerance.
In step 262, the controller 206 performs operations that result in an adjusted swaging stroke. In particular, the controller 206 alters or updates the information relating to a select stroke length that will be transmitted to the drive control mechanism 212. In the embodiment described herein, the controller 206 in step 262 transmits to the drive control mechanism a new control signal containing the updated information related to the select stroke length. It will be appreciated that ordinary trial and error methods may be used to establish the relationship between adjustments in stroke length and the corresponding change in the dimension of the work piece.
After step 262, the next work piece is placed into the swaging assembly 202 in step 252 and the process repeats. However, in step 254, the swaging assembly 202 will use the adjusted stroke length in accordance with the new control signal received from the controller in step 262. As a result of the adjusted stroke length, the resulting swaged work piece presumably will have a dimension measurement that is closer to the ideal value. The process thereafter continues in the same manner as described above.
Returning to step 260, if the controller 206 determines that the measured dimension of the work piece is within tolerance, then step 262 is skipped and the process returns directly to step 252 to swage the next work piece. Because no adjustment was performed in step 262, the next work piece is swaged using the same stroke length as the previous work piece.
It will be appreciated that the operations of FIG. 10 may suitably be controlled by a numerical or process controller, which may suitably be the controller 206. In such a case, the controller 206 (or other process control device) is operably coupled to cause operation of the swaging assembly 202, the transport mechanism 208, and the sensor assembly 204. Such process control is well known in the art.
The above described embodiments thus compensate for error in the swaging process by measuring the dimensions of a swaged work piece and adjusting the stroke length of the movable tool for the next work piece in order to compensate for the variation of the measured dimensions from a desired value. As a consequence, error due to wear on the die 214 and/or other elements may be significantly reduced, thereby increasing the time between repairs and/or maintenance of the swaging tool.
FIG. 2 shows an overall perspective view of a preferred swaging assembly 10 that may be used as the swaging assembly 202 of FIG. 1. In general, the swaging assembly includes a die assembly 12 and a swaging tool 14. The die assembly 12 is hidden from view in FIG. 2 but is shown in perspective to portions of the swaging tool 14 in FIG. 7. Referring again to FIG. 2, the swaging tool 14 includes a movable tool 16 and a frame 17.
The swaging assembly 10 operates generally to reduce the diameter of a work piece in the form of a metal tube or rod, not shown. In the exemplary embodiment described herein, the swaging assembly 10 is configured to swage bushings of various diameters. However, it will be noted that the die assembly 12 according to the present invention may be readily modified by those of ordinary skill in the art for virtually any swaging or other operation that reduces the outer diameter of a tube or rod via force.
As will be described further in detail below in connection with FIGS. 3-9, the movable tool 16 moves with respect to the frame 17 between a rest position and a swaging position. When the movable tool 16 is in the rest position, a work piece to be swaged is placed within the die assembly 12. An illustration of an exemplary embodiment of the die assembly 12 is provided in FIG. 6a. The work piece is placed in the center opening 37. The work piece may suitably be placed into position by hand, robotic arm, or by a pick and place mechanism.
Once the work piece is placed within the die assembly 12, the movable tool 16 moves from the rest position to the swaging position. In doing so, the movable tool 16 engages the die assembly 12, thereby forcing the die assembly 12 radially inward toward the work piece. The die assembly 12 converges radially upon the work piece and engages the work piece with sufficient force from multiple directions to reduce its diameter.
After the movable tool 16 is in the swaging position and the die assembly 12 has converged upon the work piece, the movable tool 16 returns to the rest position. The die assembly 12 also expands to allow for ejection of the swaged work piece and to allow insertion of a new work piece to be swaged. To allow such expansion and compression, the die assembly 12 of the present invention includes a plurality of die segments and a plurality of compressible spacing elements. As discussed in further detail below in connection with an exemplary embodiment of the die assembly 12 shown in FIGS. 6a and 6b, the compressible spacing elements tend to push the die segments away from each other, which in turn causes the die segments to move radially away from the work piece.
In accordance with the present invention, the compressible spacing elements are constructed of a polymeric material as opposed to metallic springs. The use of polymeric material reduces costs and adds convenience because polymeric material is naturally elastic and need not be formed into a specific complex geometry (i.e. a helical spring) to achieve elasticity. Further detail regarding the structure and geometry of the compressible spacing elements is given further below in connection with FIGS. 6a and 6b. 
In accordance with a different aspect of the present invention, the compressible spacing elements are secured to the die segments, preferably using fasteners. Securing the compressible spacing elements to the die segments allows for easy removal and replacement of the entire die assembly 12 as a unit. In practice, the swaging tool 14 may be used in conjunction with a plurality of die assemblies to accommodate different sizes of work pieces. Accordingly, it is desirable to facilitate removal and replacement of the die assembly 12 to reduce down time of the swaging assembly 10. In prior art designs, the springs that were used to exert separation force on the die elements of the die assembly were merely trapped between adjacent die elements. As a result, removal of the die assembly typically involved the individual removal of the die elements and springs, which was time consuming. Moreover, the springs could fall out of the die elements and would thus require retrieval. The present invention, by securing the compressible spacing elements to the die elements, eliminates the possibility of falling springs and as well as removal of individual springs.
FIG. 6a shows an exemplary embodiment of the die assembly 12 that includes hollow cylindrical compressible spacing elements, for example, the compressible spacing elements 32a and 32g. The die assembly 12 includes a plurality of die segments 30x. In FIG. 6a, only seven of the twelve die segments, namely the die segments 30a, 30b, 30c, 30d, 30e, 30f and 30g, are shown for purposes of clarity. FIG. 6b shows a cross sectional view of the die segment 30a with corresponding compressible spacing elements 32a and 32b. 
Each die segment 30x is substantially the same. Accordingly, description is provided for an exemplary die segment 30a which may be applied to the other die segments. The description of the die segment 30a and the die assembly 12 in general will be made with reference to FIGS. 6a and 6b. 
The die segment 30a includes a concave work piece engaging surface 36a, a side surface 38a, a top surface 40a, a bottom surface 41a, a tool engaging surface 42a, and a second side surface 44a. Because of the perspective view, the bottom surface 41a and the tool engaging surface 42a are not visible in FIGS. 6a and 6b. However, the tool engaging surface 42a is substantially identical to the tool engaging surface 42g of the die segment 30g, which is visible in FIG. 6a. Moreover, further detail regarding the profile of the tool engaging surface is provided in FIGS. 8 and 9. The detail of the bottom surface 41a is readily apparent from its context, as well as from features thereof drawn in phantom in FIG. 6a. 
The die segment 30a is arranged with the other die segments 30b, 30c, and so forth such that the work piece engaging surfaces 36a, 36b, 36c and so forth define a generally cylindrical opening 37. Because the exemplary die assembly 12 shown herein includes twelve die segments 30x, the work piece engaging surface 36a extends has a concave shape that defines approximately one-twelfth of the wall that substantially surrounds the opening 37. The shape of the work piece engaging surface 36a along the axial direction is largely defined by the shape of the work piece to be swaged, but for tubular or rod-like parts will include a section that is substantially uniform in the axial direction. The die segment 30a further includes a recessed extension 39a that extends from the top of the work piece engaging surface 36a to the top surface 40a. 
It will be appreciated that a work piece with multiple diameters may require die segments 30x having engaging surfaces 36x that are not axially uniform.
The side surfaces 38a and 44a extend radially outward from the work piece engaging surface 36a to the tool engaging surface 42a, thereby defining the shape of the die segment 30a as a portion of a wedge. The side surface 38a includes a first cavity 54a for receiving a part of a compressible spacing element 32a. Similarly, the second side surface 44a includes a second cavity 55a for receiving a part of another compressible spacing element 32b (not shown in FIG. 6a).
The bottom surface 41a includes two bores 50a and 52a. The first bore 50a extends to and is in communication with the first cavity 54a. The second bore 52a extends to and is in communication with the second cavity 55a. 
In the exemplary embodiment described herein, all of the compressible spacing elements 32a, 32b, 32c and so forth have substantially identical structures. Accordingly, description is only provided for the compressible spacing element 32a. The compressible spacing element 32a preferably comprises a cylindrical tube of polymeric material. However, the compressible spacing element 32a may be another shape, preferably hollow, and still retain many of the advantages of the present invention. The compressible spacing element 32a includes a first fastener aperture 46a, a first opposite fastener aperture 47a, a second fastener aperture 48a, and a second opposite fastener aperture 49a. 
In a preferred embodiment, the compressible spacing element 32a is constructed of polyurethane having a durometer reading of approximately 95a. The thickness of the walls of the hollow cylindrical element is between one-eighth inch and one-quarter inch. This combination has been found to provide adequate strength, resiliency, and compressibility for die segments that are between four to six inches in height and three to five inches in radial width.
The first fastener 34a extends upward through the first bore 50a, the first fastener aperture 46a, and the first opposite fastener aperture 47a. In this manner, the first fastener 34a serves to fasten the compressible spacing element 32a to the die segment 30a. In a similar manner, another fastener, not shown, secures the other compressible spacing element 32b to the die segment 30a. Likewise, yet another fastener, not shown, passes through a bore in an adjacent die segment, not shown, and through the second fastener aperture 48a and second opposite fastener aperture 49a to secure the compressible spacing element 32a to that adjacent die segment. In this manner, the various segments 30a, 30b and so forth are linked to each other via the compressible spacing elements 32a, 32b and so forth.
It will be appreciated that the die assembly 12 may alternatively include a different number of elements as appropriate for the implementation. Swaging die assemblies having as little as four or even two die elements can perform swaging operations sufficient in some industries. Such alternative arrangements may nevertheless benefit from many advantages provided by the present invention.
Moreover, it will be appreciated that even if helical springs are used as the compressible spacing elements, at least some of the advantages of the present invention that arise from securing the compressible spacing elements to the die segments may be obtained. In addition, the compressible spacing elements may be secured to the die elements using something other than mechanical fasteners, such as a mechanical snap fit interlock or adhesive bonding or welding. Finally, even if the compressible spacing elements are not secured to the die segment, the use of a flexible polymer as the compressible spacing elements provides many of the advantages of the present invention, including cost advantages over the use of metallic springs.
As discussed above in connection with FIG. 2, the swaging tool 14 includes a frame 17 and a movable tool 16. In general, the movable tool 16 is configured to engage the tool engaging surfaces 42a, 42b, and so forth of the die assembly 12 to place the die assembly 12 in the swaging position. The frame 17, in general, provides a housing in which the movable tool 16 and the die assembly 12 may be fixtured. While various configurations of the movable tool 16 and frame 17 may be envisioned for use in connection with the die assembly of the present invention, and indeed even for the exemplary embodiment of the die assembly 12 of the present invention shown in FIGS. 6a and 6ba, FIGS. 2-5 and 7-9 show a preferred embodiment of the swaging tool 14 for use in connection with the die assembly 12 of FIGS. 6a and 6b. 
With reference to FIGS. 3-5 and 7-9 in particular, the movable tool 16 comprises a spacer tube 18, a drive disk 20, a cylinder 22 and a drive ring 26. The frame 17 comprises a base 58, upright supports 60, 62, 64 and 66, a center base support 68, a cross member 70, a cylinder frame 72, a top plate 100, an access plate 108, a wear plate 106, upper supports 116 and 118, and an upper plate 120.
With reference to FIGS. 3 and 5 specifically, the base plate 58 is preferably rectangular and sits on a flat surface. The upright supports 60, 62, 64 and 66 are secured to the base plate 58 and extend upward therefrom to the top plate 100. The upright supports 60, 62, 64 and 66 are elongated support members that are disposed in a rectangular pattern on the base plate 58. As a result of the rectangular pattern, the upright supports 60, 62, 64 and 66 form a substantially rectangular frame interior 67 in which the movable tool 16 and die assembly 12 are disposed. To this end, the upright supports 60, 6264 and 66 are also long enough to allow the movable tool 16 and die assembly 12 to fit between the base plate 58 and the top plate 100.
The center base support 68 sits upon the base plate 58 and extends between the upright supports 60 and 64. A similar base support, not shown, sits upon the base plate 58 and extends between the upright supports 62 and 66. The cross member 70 extends between the center base support 68 and the opposing center base support referenced above.
The cylinder frame 72 houses the hydraulic cylinder 22. The cylinder frame 72 is disposed on and is secured to the top of the center base support 68, opposing center base support, and the cross member 70. The cylinder 22 includes a rod, not shown, but which is fixedly secured to the drive disk 20 by a rod nut 24. The drive disk 20 is a round disk of significant thickness. The cylinder 22 is arranged such that actuation of the cylinder 22 causes the rod, the drive disk 20 and the rod nut 24 to move vertically within the frame interior 67.
The drive disk 20 is in a driving relationship with the spacer tube 18. The spacer tube 18 has a generally cylindrical body 77, an annular flange 78, and an inner annular shelf 79. The annular flange 78 is disposed at the upper axial edge of the cylindrical body 77 and the inner annular shelf 79 is disposed within the cylindrical body offset from the upper axial edge.
The generally cylindrical body 77 has a diameter that is largely coextensive with the diameter of the drive disk 20 and the diameter of drive ring 26. Because the drive disk 20, the cylindrical body 77, and the drive ring 26 all have substantially the same radius, a balanced force may be applied throughout the circumference of the drive ring 26 during the swaging process. As will be discussed further below, it is the drive ring 26 imparts the swaging force to the die assembly 12. Accordingly, a balanced swaging force throughout the circumference of the drive ring 26 is desirable to achieve favorable swaging results and to prolong the life of the swaging tool 14.
The drive ring 26 is also a generally cylindrical body, having a largely cylindrical outer surface 74 and a chamfered or frustoconical inner surface 76. As will be discussed in further detail below, the chamfered inner surface 76 provides the translation of force between the vertical movement of the cylinder 22 and the radially inward movement of the die segments 30a, 30b, and so forth.
Referring particularly to FIG. 7, the bottom edge of the drive ring 26 is fixedly secured to the annular flange 78 of the spacer tube 18. The pressure disk 28 is secured to the inner annular shelf 79 using an arrangement that includes a plurality of fasteners 98 and a plurality of springs 82. In general, the pressure disk 28 is a substantially circular disk with a center aperture. The pressure disk 28 withstands some of the force of the swaging operation, and thus has appropriate thickness, greater than one inch, in both the axial and radial directions. The radial thickness of the pressure disk 28 is also sufficient to provide sufficient area contact between the pressure disk 28 and the bottom of the die segments 30a, 30b, and so forth.
As discussed above, the fasteners 98 and the springs 82 cooperate to define the coupling relationship between the pressure disk 28 and the spacer tube 18. With reference to FIGS. 7, 8 and 9, each of the plurality of fasteners 98 extends into a cavity 99 within the pressure disk 28. Each cavity 99 has a width that is sufficient to allow each fastener 98 to move vertically within the cavity. Each fastener 98 extends out of the cavity 99 through an aperture 99a and into an aperture in the inner annular shelf 79. Each fastener 98 includes a head portion 98a that is of a size that permits it to travel within the cavity 99 but not to pass through the aperture 99a. 
The springs 82 engage and extend between the inner annular shelf 79 and the pressure disk 28. The springs 82 are biased to provide separation force between the inner annular shelf 79 and the pressure disk 28. Accordingly, when the movable tool 16 is in the rest position, as shown in FIG. 8, the pressure disk 28 may typically rest at a point in which the springs 82 force the pressure disk 28 away from the spacer tube 18 to the further extent possible, i.e., when the head portion 98a of each fastener engages the corresponding aperture 99a. 
Referring again generally to FIGS. 5, 7, 8 and 9, the die assembly 12 is disposed generally above and preferably on top of the pressure disk 28. The pressure disk 28 and the die assembly 12 are aligned concentrically with the drive ring 26 and the spacer tube 18. The drive ring 26, which is secured to the annular flange 78 of the spacer tube 18, extends up and around the die assembly 12, as well as around much of the pressure disk in the rest position as shown in FIG. 8. It will be appreciated that the outer diameter of the pressure disk 28 is less than the smallest diameter of the inner ring surface 76 to allow the drive ring 26 to move freely about the pressure disk 28.
Several components provide resistive downward force to maintain the vertical position of the die assembly 12 during the swaging process. In accordance with another independent aspect of the present invention, such components facilitate expeditious placement and removal of the die assembly 12. The ability to quickly remove and replace the die assembly 12 has significant advantages. For example, a particular type of part may be swaged in the swaging assembly 10 for as little as a few hours or a day before another type of part is to be swaged. The ability to change out die assemblies quickly makes frequent changes in parts to be swaged more feasible.
In any event, the components of the exemplary embodiment described herein that provide the downward resistive force to the die assembly 12 include the top plate 100, a wear plate 106, and an access plate 108. Referring also to FIG. 4, the top plate 100 has a generally rectangular shape that corresponds to the rectangle defined by the position of the upright supports 60, 62, 64 and 66. Indeed, the top plate 100 is fixedly secured to the upright supports 60, 62, 64 and 66 at its comers. In the center of the top plate 100 is a circular center opening 102 that has sufficient size to allow for placement and removal of the die assembly 12 without removing the top plate 100 from the upright supports 60, 62, 64 and 66. The center opening 102 is generally circular, but also includes a number of cut out slots 104 that are spaced apart throughout the outer circumference of center opening 102. Adjacent and between the cutout slots 104 are chamfered edges 112 of the top plate 100.
The wear plate 106 is a generally circular structural disk that is aligned concentrically with and disposed on top of the die assembly 12. The wear plate 106 has a center opening having a size sufficient to allow placement and removal of the work piece therethrough. The wear plate 106 outer diameter is preferably configured such that the wear plate may be removed through the center opening 102 of the top plate 100.
The access plate 108 is a structural element that also generally circular, but includes a number of chamfered locking extensions 110 extending from the generally circular shape. The nominal outer diameter of the access plate 108 is substantially the same as, but slightly smaller than, the dimension between the chamfered edges 112 of the top plate 100. The locking extensions 110 extend from the nominal out diameter and are disposed in a pattern on the access plate 108 that corresponds to the pattern of the cut out slots 104 of the top plate 100.
The locking extensions 110 define an outer diameter that is larger than the dimension between opposing chamfered edges 112 of the top plate 100, but smaller than the dimension between opposing cut out slots 104 of the top plate 100. Accordingly, when the locking extensions 110 are aligned with the cut out slots 104, the access plate 108 may be inserted into or removed from the center opening 102. In addition, the locking extensions 110 are chamfered to allow them to be received under the chamfered edges 112 of the top plate 100. When the locking extensions 110 are disposed under the chamfered edges 112, the access plate 108 is locked in place.
During normal swaging operations, the access plate 108 is locked in place as shown in FIGS. 8 and 9. In that position, the access plate 108 engages the wear plate 106, which in turn, as discussed above, engages the die assembly 12. The combined structure of the top plate 100, the access plate 108 and the wear plate 106 thus serves to secure the die assembly in its vertical or axial position.
It is noted that the wear plate 106 need not be a separate element but instead may constitute an extension of the access plate 108. However, the use of a separate wear plate 106 as shown herein has advantages over a single piece construction. In particular, it has been found that repeated swaging operations cause wear-related damage to the surface of a wear plate such as the wear plate 106. Over time, the accumulated damage to the wear plate 106 can adversely affect the swaging process and the wear plate 106 must be replaced. If the wear plate 106 and the access plate 108 are integrally formed, then the replacement cost is substantially higher. Accordingly, by using a separate wear plate 106, the reconditioning of the swaging assembly 10 to remedy accumulated wear-related damage to the wear plate becomes appreciably less expensive.
In general, the work piece to be swaged is fixtured within the center opening 37 of the die assembly 12. To this end, in reference to FIG. 7, the work piece is supported by a bushing fixture 90, an eject cylinder 84, and preferably an adapter 88. The eject cylinder 84 is disposed within the cylindrical body 77 of the spacer tube 18 and is configured to remain stationary when the drive disk 20, spacer tube 18 and drive ring 26 move vertically. To this end, the eject cylinder 84 is fixtured to the upright support 66 using a fixturing support, not shown, that passes through an opening 81 in the spacer tube 18. The eject cylinder 84, however, is operable to move vertically in order to eject the work piece from the die assembly 12, as discussed further below.
The bushing fixture 90 is coupled to the eject cylinder 84 through the adapter 88. The eject cylinder 84 includes a threaded extension 86 onto which the adapter 88 is disposed. Accordingly, the adapter 88 is internally threaded to receive the threaded extension 86. The adapter 88 is an elongated supporting extension element that is illustratively cylindrical. However, the adapter 88 may be of any cross sectional shape as long as it operates as a spacer between the eject cylinder 84 and the bushing fixture 90.
The bushing fixture 90 comprises a fixture base 92, an elongated spindle 94, and a threaded anchor 96. The bushing fixture 90 is illustrative of a work piece fixture that is particularly suitable for work pieces in the form of bushings. Other fixtures may be developed by the ordinary skilled artisan for other types of work pieces. In the illustrative embodiment, the threaded anchor 96 is rotatably received into the adapter 88 to secure the bushing fixture 90 within the frame interior 67. The spindle 94 and base 92 are configured to receive the bushing and support the bushing within the center opening 37 of the die assembly 12.
The upper portions of the frame 17 shown in FIG. 4 are employed primarily to assist in automating the process of fixturing the work piece within the die assembly 12 in the frame interior 67. The upper portions of the frame 17 include the upper supports 116 and 118, the upper plate 120, the hold down cylinder 122, the hold down button 124. The upper supports are elongated structural members that extend upward from and are secured to the top plate 100 at the comers of the top plate 100 that are secured to the upright supports 62 and 66. The upper plate 120 comprises a relatively flat support plate that is secured to and supported by the upper supports 116 and 118. The upper plate 120 provides an overhead anchor for the hold down cylinder 122.
The hold down cylinder 122 is an ordinary hydraulic cylinder that is secured to and extends downward from the upper plate 120. The hold down button 124 is a cylindrical element that is secured to the piston, not shown, of the hold down cylinder 122 and extends therewith. The hold down cylinder 122 and hold down button 124 engage the work piece when it is fixtured in the die assembly 12. More particularly, the hold down cylinder 122 and hold down button 124 ensure the that the work piece is adequately fixtured in the swaging tool 14 by reference to a predetermined cylinder position value. In other words, the hold down cylinder 122 is configured to provide feedback regarding its position and that position can be compared to the proper position for the hold down cylinder 122 if the bushing/work piece is properly fixtured. If the hold down cylinder 122 is in the proper position, then the work piece is properly fixtured and the swaging operation may commence. If not, however, then the swaging operation should not occur and corrective measures may be required. Such features are particularly useful in automating the fixturing process.
In addition to the above elements, the swaging tool 14 further includes a device that provides position feedback for the cylinder 22 of the movable tool 16. In the exemplary embodiment described herein, the position feedback device is a linear velocity displacement transducer (“LVDT”). As shown in FIG. 5 in exploded view, the LVDT includes an LVDT encoder 126, an armature 128, an armature mount 130, and a clamp 132. The armature mount 130 and the clamp 132 are fixedly secured to the upright support 66. The LVDT encoder 126, armature, and other elements are arranged as is well known in the art to provide position feedback regarding the travel of the cylinder 22.
The operation of the swaging tool 10 will be described with reference to performing a swaging operation on a work piece in the form of a bushing that is delivered to the vicinity of the center opening 37 of the die assembly 12. To this end, a pick and place device, robotic arm, or other automated device may be used to dispose the work piece through the circular center opening 102 of the top plate 100, through the access plate 108 and the wear plate 106 onto the spindle 94 of the bushing fixture 90 in the center opening 37 of the die assembly 12. (See FIG. 8). During the fixturing process, the movable tool 16 is in the rest position.
After the workpiece has been placed into position, the hold down cylinder 122 moves the hold down button 124 to engage the work piece. Once engaged, the hold down cylinder 122 the hold down button 124 engage the work piece until a predetermined position is reached. This ensures that the work piece is properly fixtured in automated processes. In alternative embodiments, the work piece may be manually fixtured. In such cases, the hold down cylinder 122 and associated components would not be required.
Once properly fixtured, the movable tool 16 moves from the rest position (FIG. 8) to the swaging position (FIG. 9). To this end, the cylinder 22 forces the drive disk 20 in a vertically upward direction. The drive disk 20 thus drives the spacer tube 18 in the same direction. As the spacer tube 18 moves vertically upward, it imparts and upward force on the drive ring 26.
In addition, as the spacer tube 18 moves upward, it moves toward the pressure disk 28. Although some of the force of the upward movement is translated through the inner annular shelf 79 and the springs 82 to the pressure disk 28, the pressure disk 28 cannot move vertically. In particular, the pressure disk 28 cannot move because it is trapped by the interfering placement of the die assembly 12, the wear plate 106, the access plate 108 and the top plate 100. Accordingly, the die assembly 12 likewise does not move vertically.
Referring specifically to FIGS. 8 and 9, as shown in FIG. 9, as the spacer tube 18 moves upward, the springs 82 compress to allow the relative movement between the annular shelf 79 and the pressure disk 28. Moreover, as the drive ring 26 moves upward, its inner surface 76 engages the tool engaging surface 42 of the each of the die segments 30a, 30b, and so forth. The corresponding sloped surfaces of the inner surface 76 of the drive ring 26 and the tool engaging surfaces 42 cooperate to translate the vertical or axial movement of the drive ring 26 to radially inward movement of the die segments 30a, 30b and so forth.
The radially inward movement of the die segments 30a, 30b and so forth converge upon the work piece within the center opening 37. The work piece engaging surfaces 36a, 36b, and so forth engage the work piece and forcibly reduce its diameter, thereby performing the swaging operation. The amount of swaging is controlled by the vertical stroke of the cylinder 22. The LVDT encoder 126 is used as closed loop feedback to tightly control the vertical stroke of the cylinder.
During the radially inward movement of the die segments 30a, 30b, and so forth, the compressible spacing elements 32a, 32b and so forth become compressed along their axial direction. The axial compression typically causes temporary radial displacement of the compressible spacing element material. For example, a relatively long, thin compressible spacing element 32a compresses to a relatively short, fat compressible spacing element 32a. To this end, referring to FIGS. 6a, 8 and 9, it is noted that the cavities 54a, 54b and so forth and 55a, 55b and so forth must be configured to have room for the radial expansion of the compressible spacing elements 32a, 32b and so forth. In other words, the radial dimension of each cavity 54x and 55x must exceed the outer radius of the uncompressed compressible spacing element 32x. 
It is noted that during the movement from the rest position to the swaging position, the disk fasteners 98 move with the annular shelf 79, to which they are secured. The disk fasteners 98 move vertically within the cavity 99 formed in the pressure disk 28.
After the swaging force has been applied, the movable tool 16 returns to the rest position as shown in FIG. 8. To this end, the cylinder 22 moves the drive disk 20 vertically downward. Gravity and/or the decompression force of the springs 82 cause the spacer tube 18 and the drive ring 26 to move downward. In addition, the compressing spacing elements 32a, 32b, and so forth impart a separating force between adjacent die segments 30a, 30b, and so forth. This separation force is translated by the configuration of the die assembly 12 to a radially outward force. The separation force urges the die assembly 12 into its rest or expanded position in which the center opening 37 is expanded. When the center opening 37 is expanded, the work piece may be replaced. Once the work piece is replaced, the above described process may be repeated to swag the new work piece.
Accordingly, the embodiment describe above illustrates one environment in which a die assembly according to the present invention may be used. However, various types of movable tools and/or frame configurations may be employed that still require a die assembly that includes multiple segments with compressible spacing elements therebetween. Many of the advantages of the present invention translate to any such embodiments.
In addition, the swaging assembly 10 described above includes one or more independent inventions either partially related or entirely unrelated to the inventive die assembly described herein.
In any event, it will be appreciated that the above described embodiments are merely illustrative, and that those of ordinary skill in the art may readily devise their own implementations that incorporate the principles of the present invention and fall within the spirit and scope thereof. For example, as discussed above, the compressible spacing element used in the die assembly of the present invention may take many forms and still provide advantages over the metal spring configuration. In particular, a compressible spacing element constructed of an elastic material such as polymer may be fashioned to provide a spring action that require less manufacturing complexity than a metal spring. Indeed, any shaped device that is axially continuous, i.e, not exclusively helical, provides at least some of the advantages over the use of metal springs. Hollow elements are particularly advantageous because they provide more room for the compressed polymer to expand radially and allow more axial compression. Hollow cylinders are most advantageous.

## Claims

1. A swaging system, comprising:
a movable tool operable to exert force on a die, the die configured to reduce a dimension of a work piece responsive to the exerted force, the dimension reduction having a relationship to a stroke of the movable tool; 
a sensor operable to obtain information including a measurement of the reduced dimension of the work piece, the sensor operable to generate a measurement signal representative of the obtained information, wherein the sensor comprises a laser sensor; and 
a controller operably coupled to receive the measurement signal from the sensor, the controller operable to cause adjustment the stroke of the movable tool responsive to the measurement signal.

2. The swaging system of claim 1 wherein the movable tool includes a hydraulic cylinder.

3. The swaging system of claim 1 further comprising a plurality of die segments and wherein:
the movable tool is configured to cause the plurality of die segments to converge upon the work piece.

4. The swaging system of claim 3 wherein the movable tool further includes a hydraulic cylinder operable to impart axial movement to a drive ring, the drive ring coupled to the plurality of die segments to impart radial movement during said axial movement of the drive ring.

5. The swaging system of claim 1 further comprising means for transporting the work piece to a position that is proximate to the sensor.

6. A swaging system, comprising:
a movable tool operable to exert force on a die, the die configured to reduce a dimension of a work piece responsive to the exerted force, the dimension reduction having a relationship to a stroke of the movable tool; 
a stroke control device operable to control the movable tool in accordance with a predefined stroke; 
a sensor operable to obtain information including a measurement of the reduced dimension of the work piece, the sensor operable to generate a measurement signal representative of the obtained information, wherein the sensor comprises a laser sensor; 
a controller operably coupled to receive the measurement signal from the sensor, the controller operable to cause the stroke control device to adjust the predefined stroke of the movable tool responsive at least in part to the measurement signal.

7. The swaging system of claim 6 wherein the movable tool includes a hydraulic cylinder and the stroke control device is a hydraulic servo controller unit.

8. The swaging system of claim 7 wherein the stroke control device includes a linear velocity displacement encoder.

9. The swaging system of claim 6 further comprising a plurality of die segments and wherein:
the movable tool is configured to cause the plurality of die segments to converge upon the work piece.

10. The swaging system of claim 9 wherein the movable tool further includes a hydraulic cylinder operable to impart axial movement to a drive ring, the drive ring coupled to the plurality of die segments to impart radial movement during said axial movement of the drive ring.

11. The swaging system of claim 6 further comprising means for transporting the work piece to a position that is proximate to the sensor.

12. A method of performing a swaging operation on a plurality of work pieces, comprising:
a) employing a swager to reduce a dimension of a first work piece, the reduced dimension of the first work piece having a first value; 
b) obtaining a measurement of a dimension of the first work piece using a laser; 
c) adjusting the swager based at least in part on the obtained measurement; and 
d) employing the swager to reduce a dimension of a second work piece, the reduced dimension of the second work piece having a second value, a difference between the first value and the second value based at least in part on the obtained measurement.

13. The method of claim 12, wherein
step a) further comprises using a first stroke of a movable tool to reduce the dimension of the first work piece; and 
step d) further comprises using a second stroke of the movable tool to reduce the dimension of the second work piece, a difference between the first stroke and the second stroke based at least in part on the obtained measurement.

14. The method of claim 13 wherein step a) further comprises employing a hydraulic cylinder to cause movement corresponding to the first swaging stroke.

15. The method of claim 14 wherein step a) further comprises controlling the movement of the hydraulic cylinder using a stroke length control device.

16. The method of claim 14 wherein step a) further comprises controlling the movement of the hydraulic cylinder using a hydraulic servo controller device.

17. The method of claim 12 further comprising, before step b), moving the first work piece to a sensor device operable to generate information regarding a measurement of the dimension of the first work piece.

18. The method of claim 12 wherein the dimension of the first work piece comprises an outer diameter of the first work piece and the dimension of the second work piece comprises an outer diameter of the second work piece.

19. The method of claim 12 wherein the step of employing a swager comprises the step of
moving a hydraulic cylinder to impart axial movement to a drive ring, the drive ring coupled to a plurality of die segments to impart radial movement of the die segments during said axial movement of the drive ring.