Thread rolling, Roll forming, Washer and sleeve assembly
Thread Rolling Machines
Offering a wide range of Thread Rolling Machines suitable for small or large components for the automotive, building and general industries.
For Micro parts
Micro thread rollers
The smallest thread rolling machine inspired by the I-Thread concept, the micro thread rolling machine with dies W00/W000, is available for the high-speed production of very precise miniature screws. The machine is equipped with the latest technologies, such as an innovative tool holder and an insertion system driven by a torque motor to insert the miniature blanks into the dies with ultra-precision. The most innovative feature is the slide body, which runs on linear guides (with ball bearings) to ensure very high accuracy for the rolling process, allowing parts to be produced with very high precision and reliability. The RP020 is driven by an innovative double helical drive belt that connects the brushless main motor to an absolute master encoder. This new type of double spiral belt drive enables higher torque and precision.
The machine is equipped with the same advanced features as the Ingramatic I-Thread machines, such as the self-learning adjustment of the starter unit. The infeed stroke can be adjusted via the control panel or the electronic handwheel, eliminating the need for technicians to make manual adjustments with service wrenches, ensuring fast and accurate dimensional changes. To guarantee durability and precision, the frame is made of cast iron alloy and the SC-Matic interface ensures the management of motorized settings.
The micro roller is equipped with an innovative soundproof housing that makes the machine comfortable and modern for the new generation of Industry 4.0.
Efficient thread rollers for demanding applications
Thread rollers with single starter
The new thread rolling machines, which are equipped with a single starter unit, are available from size W1015/TR1 to W20/TR4 and are suitable for the production of fasteners for any type of industry. The thread rolling machines can roll self-tapping screws, automotive parts, heat-treated parts and special profiles. The key features of the machines are the starter unit driven by a direct drive motor and the machine frame made of pearlitic spheroidal cast iron, including the fixed rolling die block, which turns the machine into a precise thread rolling machine. The new drive unit is driven by a high-precision planetary gearbox with clutch/brake unit, which is unique for this machine size. This new drive type with epicyclic reduction gear offers a cascading reduction of the gearbox and favors higher torque and precision when processing hardened parts. The height adjustment of the feed rails and the vibratory feeder is motorized to facilitate adaptation to the length of the parts. The machine is equipped with a vibratory bowl feeder as standard, which is housed in a soundproof casing.
The most innovative feature is the new starter unit. It is controlled by a torque motor. The infeed stroke can be adjusted via the control panel or the electronic handwheel, eliminating the need for manual adjustment with service wrenches and ensuring quick and accurate dimensional changes. Quality is managed by a sorting flap that ejects parts when the load monitor detects deviations, enabling the production of perfect parts.
The modular system makes it possible to install the R1 or R2 washer assembly units in the machine and to integrate a station for the automatic feeding of headless parts VP with a control of the blank orientation by a video camera and a station for turning the parts in case of misalignment before insertion into the starter unit.
Efficient thread rollers for demanding applications
Thread rollers with double starter
The new thread rolling machines with double starter are equipped with the patented double starter unit driven by servomotors and the revolutionary self-learning adjustment of the starter blade. The machine is extremely rigid and robust thanks to its brand new exclusive design and reinforced machine frame. From the W30/TR5 up to the W70, Ingramatic installs a hydrostatic slide bearing system optimized for high load capacity and significantly dampens the rolling load of threaded automotive bolts after heat treatment as well as the rolling of special profiles and parts made of exotic materials. Special bronze bushes are supplied with pressure lubrication via a distributor so that the hydrostatic pockets can form an oil film that evenly distributes the rolling load and absorbs the high forces generated between the tools when the part is rolled. There are two solutions for feeding blanks into the feed rails: with a V-group consisting of a vibratory feed unit connected to the thread rolling machine for blanks up to 140 mm under head or with a vertical overhead conveyor with a vibratory hopper for longer parts up to 440 mm to load the thread rolling machine smoothly and quickly.
The thread rollers with double insertion units are equipped with the “M group”, which allows the motorization of the drive unit and the position of the slide for a quick and accurate control of the tool adjustment. All settings are stored for each part and can be recalled to continue with the automatic set-up of the machine.
The machines can be equipped with a washer assembly unit that can be quickly changed over and is suitable for assembly of very large washers. Like all Ingramatic thread rollers, the machine is equipped with a sorting flap to eject parts if the load monitoring detects deviations.
For Special Materials
Warm Former Threaders
To compliment the Sacma warm former line, Ingramatic features the Warm Forming Threaders. Combining the heavy duty design and features of the revolutionary I-Thread, the WF provides a significant increase in thread quality, productivity and efficiency by rolling all shapes of bolts, screws, and parts made of materials difficult to roll, such as Waspaloy®, Titanium alloy, A286 and Inconel®. The machine features include dedicated feeding rails for the installation of an induction coil with an exclusive design, a generator, a chiller, a high frequency inverter box, an optical pyrometer, and a cooled stationary die holder. A set of selectors manages the parts through the induction coil to ensure the parts are consistently rolled at the correct temperature.
The repeatability of the heating is assured by using a longer induction coil compare what it is existing on the market with the home-made solution or a rollers adapted with a heating unit. As per Sacma headers, the induction coil design allows the system to warm wide range of materials with only one induction coil. Consequently, this Warm Forming roller provides quick changeover making it ideal for the small lot sizes in the Aerospace fastener market. The machine is equipped with a rejection gate to reject parts when the load monitor detects deviations or the optical pyrometer read a blank not at the right temperature. This device allows to ensure an absolute production quality.
Combined Thread Rollers
Thread Rollers with washer assembly units „R1“ / „R2“ or sleeve assembly unit
Ingramatic offers washer assembly units for one or two washers, an important, versatile accessory of a thread rolling machine. The washer assembly units place one or two washers or a sleeve on a blank before thread rolling so that they can no longer be removed.
The 3rd generation assembly units have a modular design so that a washer assembly unit can easily be replaced by a sleeve assembly unit.
Combined Thread Rollers
Thread rollers for parts with and without head „VP“
In this model, INGRAMATIC combines the thread and form rolling of normal screws with heads with that of parts without heads, such as threaded pins or grub screws. For this the machine is equipped with a further blank feeding system with a vibratory bowl feeder, a video camera to record the position orientation with a turning device and a tube feeding system with a separator for insertion into the rolling dies. This thread roller deliberately enables both types of parts to be processed, as it is often not worthwhile for customers to purchase a machine specifically for this purpose. However, if there is sufficient capacity utilization and the thread roller is to be operated purely with headless parts, these models can of course also be supplied without the rail feed elements.
Combined Thread Rollers
Flat die thread rollers with segment die thread rolling unit „RR“
The Ingramatic RR models, in which the machine is equipped with an upstream round segment rolling unit in addition to the flat die thread rolling unit, offer a further combination of several work steps in a single pass.
Here, for example, you can apply threads with two different diameters or combine thread rolling with the form rolling of grooves or knurls at the other end of the shank, especially for long parts. This can result in valuable savings, as there is no need for intermediate storage and refeeding for a new pass.
In addition, this combined thread roller can also be equipped with a washer assembly station to incorporate a further work step in one pass. The earlier, pure Ingramatic “GR” round segment rollers are now also available again in two models.
For large & heavy parts
Maxi thread rollers
The large profile and thread rolling machine model RP920 (W70/TR9) for the production of large and heavy fasteners. The RP920 has a unique machine frame design that integrates the fixed die block and the patented double starter unit. The machine is equipped with a new cabin design and all the I-Thread features that make the machine the most innovative and precise large thread rolling machine in the world, consisting of: exclusive design and reinforced machine frame, self-learning and fully motorized adjustments, double starter unit driven by servomotors, new SC-Matic panel, drive unit with planetary gearbox, motorized track adjustment, slide body with hydrostatic guide system and fast diameter change system.
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More information
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