Forged pup joints entering the threading machine can vary by up to ±1 inch, making consistent positioning and accurate threading a significant production challenge. Traditional measurement methods would have added complexity, maintenance requirements, and additional hardware to the system.

 

To overcome this challenge, a custom sensorless measurement and positioning system was developed using servo motion control technology. By leveraging servo torque feedback and axis position data, the system accurately determines pup joint dimensions and position without the use of external sensors, ensuring precise feeding and repeatable threading performance.

 

The solution was fully integrated with an Allen-Bradley control platform and incorporates a steel-reinforced belt drive for high-speed, reliable operation.

 

The result is a robust, low-maintenance automation system that improves accuracy, increases throughput, and delivers consistent performance despite variations in incoming material.