In-die detection sensor for tapping assembly

Abstract

A die assembly including an in-die tapping sensor assembly having a magnetic sensor and magnet for detecting the position of the tapping head is disclosed. For example, the magnetic sensor may be disposed along an outer housing cooperating with an actuator having a tip configured to receive the tapping head. The actuator may include the magnet such that when the magnet and magnetic sensor are aligned the magnet triggers the magnetic sensor and the tapping head is retracted.

What is claimed is: 
     
         1 . A die assembly comprising:
 a die;   a tapping assembly cooperating with the die, the tapping assembly comprising a tapping head and a tapping sensor assembly, the tapping sensor assembly comprising:
 an outer housing defining a cavity; 
 an actuator comprising a tip arranged to cooperate with the tapping head, the actuator at least partially received in the cavity; 
 a magnetic sensor; and 
 a magnet disposed wherein the magnetic sensor or magnet disposed along the outer housing and the other of the magnetic sensor or magnet is disposed along the actuator such that when the actuator is actuated by the tapping head, the magnet is aligned or misaligned with the magnetic sensor and the magnetic sensor is activated. 
   
     
     
         2 . The die assembly of  claim 1 , wherein the tip is rotatable. 
     
     
         3 . The die assembly of  claim 2 , wherein the housing and the actuator include a non-magnetic material. 
     
     
         4 . The die assembly of  claim 1 , wherein the magnet is arranged on the actuator. 
     
     
         5 . The die assembly of  claim 1 , wherein the actuator defines a fluid passage to deliver a fluid from a first end of the sensor assembly to a second end of the sensor assembly such that the tip is lubricated while cooperating with the tapping head. 
     
     
         6 . The die assembly of  claim 1 , further comprising a controller to retract or actuate the tapping head when the magnet triggers the magnetic sensor. 
     
     
         7 . The die assembly of  claim 1 , wherein the tapping head deforms a component during operation. 
     
     
         8 . The die assembly of  claim 7 , wherein the tapping head pierces a component during operation. 
     
     
         9 . A tapping sensor assembly comprising:
 a hollow body defining a cavity;   an actuator at least partially disposed in the cavity, the actuator comprising a rotatable receiving head; and   a magnet or a magnetic sensor arranged along the actuator, and the other of the magnet or the magnetic sensor being arranged along the hollow body such that as the actuator moves from a first position to a second position in the hollow body, the magnet activates the magnetic sensor indicating a position of the actuator relative to the hollow body.   
     
     
         10 . The tapping sensor assembly of  claim 9 , wherein the receiving head receives a tapping fluid through a fluid passage defined in the actuator. 
     
     
         11 . The tapping sensor assembly of  claim 9 , wherein the hollow body comprises a first material and the actuator comprises a second material that is different from the first material. 
     
     
         12 . The tapping sensor assembly of  claim 11 , wherein the first material is brass and the second material is aluminum. 
     
     
         13 . A tapping assembly comprising a tapping head arranged to cooperate with the receiving head of the tapping sensor assembly of  claim 9  such that the actuator is actuated from the first position to the second position or vice versa. 
     
     
         14 . A method of making a part comprising:
 positioning an unshaped component in a die assembly adjacent a mold;   shaping the unshaped component by applying pressure to the unshaped component such that it contacts the mold to form a shaped component; and   tapping the unshaped component or shaped component with a tapping assembly comprising a tapping head that cooperates with a sensor assembly comprising an actuator with a receiving head arranged to cooperate with the tapping head, the actuator comprising a magnet such that when the receiving head receives the tapping head or a component disposed between the tapping head and the receiving head, the actuator is actuated to activate a magnetic sensor with the magnet.   
     
     
         15 . The method of  claim 14 , wherein the component is disposed between the tapping head and the receiving head. 
     
     
         16 . The method of  claim 14 , wherein tapping occurs during shaping. 
     
     
         17 . The method of  claim 14 , wherein the receiving head is rotatable during tapping. 
     
     
         18 . The method of  claim 14 , wherein a tapping fluid is applied the tapping head during operation through the sensor assembly. 
     
     
         19 . The method of  claim 14 , wherein the magnet activates the magnetic sensor when the magnet and the magnetic sensor are aligned. 
     
     
         20 . The method of  claim 14 , wherein the shaped component is an automotive component.