Tool for assembling main assembly using single stroke

Abstract

A tool for attaching a first workpiece and a second workpiece to each other and to a support structure includes a housing and a plunger. The housing includes a body, a neck, and a shoulder. The shoulder is arranged between the body and the neck, and the outer diameter of the shoulder is larger than that of the body. A bore extends from a first end within the body to a distal end of the neck. A plunger is disposed within the bore and extends from the distal end of the neck. The plunger is biased in a first direction away from the shoulder and includes a clamp operable to extend away from an outer surface of the plunger in a deployed state to engage an inner surface of the first workpiece.

Description

Technical Field

[0001] The present invention generally relates to a tool for assembling a first workpiece and a second workpiece onto a support structure. For example, the tool can be configured to assemble a transmission in which a bearing is mounted to a bearing support to form a subassembly, which is then mounted to a pinion shaft. In such an example, the bearing is the first workpiece, the bearing support is the second workpiece, and the pinion shaft is the support structure. Background Art

[0002] The information provided in this section is for the purpose of generally presenting the background of the present disclosure. To the extent described in this section, the work of the presently named inventors, as well as aspects of the description that may not qualify as prior art at the time of filing, are neither explicitly nor implicitly admitted to be prior art with respect to the present disclosure.

[0003] Currently, a first workpiece is assembled onto a second workpiece using a first tool at a first workstation. The first tool is configured to position the first workpiece to align with the second workpiece and then press the first workpiece onto the second workpiece. This can be accomplished by holding one of the first and second workpieces in position and pressing the other of the first and second workpieces onto the held workpiece to form a subassembly. The subassembly is then transferred to a second workstation. The transfer can be done manually or automatically by a conveyor belt or a robotic arm.

[0004] The second workstation includes a second tool that is different from the first tool. The second tool assembles the subassembly onto the support structure. In order to assemble the subassembly onto the pinion shaft, the pinion shaft is pressed into a hole of the subassembly. During the assembly of the subassembly onto the pinion shaft, the hole of the subassembly must be aligned with the pinion shaft prior to assembly. In particular, the subassembly is press-fit onto the pinion shaft, which requires the second tool to apply pressure. Therefore, if the hole of the subassembly is not properly aligned with the pinion shaft, the subassembly and / or the pinion shaft may be damaged.

[0005] The second workstation can be equipped with a sensor for detecting the alignment of the subassembly relative to the pinion shaft. However, the sensor adds cost, and the operation of the second tool depends on the function of the sensor. The sensor can be an optical sensor, such as a camera, or a proximity sensor, such as an infrared light. Therefore, if the sensor is blocked and cannot detect the subassembly, the worker must clear the obstruction.

[0006] Although conventional tools are sufficient to assemble the first workpiece to the second workpiece to form a subassembly, and assemble the subassembly to the support structure, a large number of workstations and steps are required. Therefore, it is desirable to reduce the number of workstations, parts, and steps required to assemble the first workpiece, the second workpiece, and the support structure to improve efficiency. Summary of the invention

[0007] In one configuration, a tool for attaching a first workpiece and a second workpiece to each other and to a support structure includes a housing and a plunger. The housing includes a body and a neck extending from the body. The outer diameter of the neck is less than the outer diameter of the first workpiece. The housing also includes a shoulder disposed between the body and the neck. The outer diameter of the shoulder is greater than the outer diameter of the body, the outer diameter of the neck, and the inner diameter of an aperture formed in the second workpiece. The housing also includes a hole extending from a first end in the body to a distal end of the neck.

[0008] The plunger includes a first end disposed within the bore and a second end extending from a distal end of the neck, the plunger being biased in a first direction away from the shoulder and including a clamp operable to extend away from an outer surface of the plunger in an expanded state to engage an inner surface of the first workpiece.

[0009] The tool may include one or more of the following optional features. For example, the tool may include a biasing element disposed within the hole and engaging the first end of the hole and the first end of the plunger. In such aspects, the biasing element may be a spring, such as a coil spring.

[0010] In one configuration, the tool includes a rod disposed within the plunger, the rod being operable to selectively engage the clamp to move the clamp from a retracted state to an extended state. In such an aspect, the rod is slidably disposed within the plunger.

[0011] In one arrangement, the second end of the plunger includes a beveled surface.

[0012] In one configuration, the outer diameter of the plunger is smaller than the inner diameter of the support structure.

[0013] The shoulder may define an engagement surface operable to engage an outer surface of the second workpiece proximate the aperture of the second workpiece.

[0014] In one arrangement, the first workpiece may be a bearing having an inner ring having an outer diameter that is smaller than an outer diameter of the neck.

[0015] In another configuration, a method for attaching a first workpiece and a second workpiece together and to a support structure includes moving a tool in a first direction toward the first workpiece, the tool having a body, a neck, a shoulder, and a plunger slidably disposed within the body. The method includes engaging a distal end of the neck with a top surface of the first workpiece and extending the plunger into an aperture of the first workpiece as the tool moves in the first direction. The method also includes moving a clamp of the plunger from a retracted state to an extended state to engage an inner surface of the aperture of the first workpiece, and moving the tool toward the second workpiece in the first direction to engage the shoulder with an outer surface of the second workpiece near the aperture of the second workpiece. The method also includes pressing the first workpiece into the aperture of the second workpiece to form a subassembly as the tool moves in the first direction, and pressing the subassembly onto the support structure as the tool continues to move in the first direction.

[0016] In one configuration, the plunger is biased in a direction away from the body. In such an aspect, the biasing element is located within the bore of the body between the first end of the bore and the first end of the plunger. The biasing element can be a coil spring within the bore of the body. Additionally or alternatively, the method can include providing a ramp for the distal end of the plunger.

[0017] In one configuration, engaging the distal end of the neck with the top surface of the first workpiece includes engaging the distal end of the neck with the inner ring of the first workpiece. In this configuration, moving the clamp of the plunger from the retracted state to the extended state to engage the inner surface of the aperture of the first workpiece includes engaging the inner surface of the inner ring of the first workpiece.

[0018] In one configuration, moving the clamp of the plunger from the retracted state to the deployed state to engage the inner surface of the aperture of the first workpiece includes suspending the first workpiece by the clamp.

[0019] The distance from the bottom surface of the shoulder to the distal end of the neck can be substantially equal to the height of the second workpiece. In addition, moving the clamp of the plunger from the retracted state to the deployed state can include moving a rod disposed within the plunger into contact with the clamp. Moving the rod into contact with the clamp can include translating the rod relative to and within a hole defined by the plunger. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.

[0021] Figure 1 is a perspective view of the main assembly showing the first workpiece, the second workpiece and the support structure assembled together;

[0022] Figure 2 yes Figure 1 An exploded view of the components;

[0023] Figure 3 Is configured as a structure Figure 1 A side view of an assembly of a tool;

[0024] Figure 4 It is used to construct Figure 1 A cross-sectional view of a plunger of the assembly, the cross-sectional view being taken along the length of the plunger;

[0025] Figure 5 yes Figure 4 A top view of the plunger is shown;

[0026] Figure 6 It is used to hold the first workpiece. Figure 3 a cross-sectional view of the tool shown;

[0027] Figure 7 yes Figure 6 a cross-sectional view of the tool further moved in the first direction, showing the tool pressing the support structure;

[0028] Figure 8 yes Figure 7 a cross-sectional view of the tool further moved in the first direction, showing the tool centering itself on the support structure;

[0029] Fig. 9 yes Figure 8 A cross-sectional view of the tool further moved in the first direction, showing the housing of the tool pressing the first workpiece into the second workpiece;

[0030] Fig.10 yes Fig. 9 a cross-sectional view of the tool further moving in the first direction, showing the first workpiece and the second workpiece moving together and pressing against the support structure;

[0031] Fig.11 yes Fig.10 showing the tool moved back to the starting position; and

[0032] Fig.12 is a flow chart illustrating a method for attaching a first workpiece and a second workpiece together and to a support structure.

[0033] Corresponding reference characters indicate corresponding parts throughout the several views. DETAILED DESCRIPTION

[0034] Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that the present disclosure will be thorough and will fully convey the scope of the present disclosure to those of ordinary skill in the art. Specific details, such as examples of specific components, devices, and methods, are set forth to provide a thorough understanding of the configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be implemented in many different forms, and that the specific details and exemplary configurations should not be construed as limiting the scope of the present disclosure.

[0035] The terms used herein are only for describing specific exemplary configurations, not for limiting. As used herein, the singular articles "a", "an" and "the" may also be intended to include plural forms, unless the context clearly indicates otherwise. The terms "comprise", "include", "contain" and "have" are inclusive, thus specifying the presence of features, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, steps, operations, elements, parts and / or groups thereof. The method steps, processes and operations described herein should not be interpreted as necessarily requiring them to be performed in the specific order discussed or shown, unless specifically identified as an execution order. Additional or alternative steps may be adopted.

[0036] When an element or layer is referred to as being "on another element or layer," "engaged to," "connected to," "attached to," or "coupled to" another element or layer, it may be directly on, engaged, connected, attached to, or coupled to another element or layer, or there may be intermediate elements or layers. Conversely, when an element is referred to as being "directly on another element or layer," "directly engaged to," "directly connected to," "directly attached to," or "directly coupled to" another element or layer, there may be no intermediate elements or layers. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0037] The terms first, second, third, etc. can be used here to describe various elements, components, regions, layers and / or parts. These elements, components, regions, layers and / or parts should not be limited by these terms. These terms are only used to distinguish each element, component, region, layer or part. Terms such as "first", "second" and other numerical terms do not imply order or sequence unless the context clearly indicates. Therefore, the first element, component, region, layer or part discussed below can be referred to as the second element, component, region, layer or part, without departing from the teaching of the example configuration.

[0038] In this application, including the definitions below, the term module may be replaced by the term circuit. The term "module" may refer to or be part of an application specific integrated circuit (ASIC), or include an application specific integrated circuit (ASIC); a digital, analog, or mixed analog / digital discrete circuit; a digital, analog, or mixed analog / digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor (shared, dedicated, or group) that executes code; a memory (shared, dedicated, or group) that stores code executed by the processor; other suitable hardware components that provide the functionality; or a combination of some or all of the above, such as in a system on a chip.

[0039] The term code used above may include software, firmware and / or microcode, and may refer to a program, a routine, a function, a class and / or an object. The term shared processor includes a single processor that executes some or all of the code from multiple modules. The term group processor includes a processor that executes some or all of the code from one or more modules in combination with an additional processor. The term shared memory includes a single memory that stores some or all of the code from multiple modules. The term group memory includes a memory that stores some or all of the code from one or more modules in combination with an additional memory. The term memory may be a subset of the term computer-readable medium. The term computer-readable medium does not include transient electrical signals and electromagnetic signals propagated through the medium and can therefore be considered to be tangible non-transitory memory. Non-limiting examples of non-transitory memory include tangible computer-readable media, including non-volatile memory, magnetic memory, and optical memory.

[0040] The apparatus and methods described in this application may be implemented in part or in whole by one or more computer programs executed by one or more processors. The computer program includes processor executable instructions stored on at least one non-transitory tangible computer readable medium. The computer program may also include and / or rely on stored data.

[0041] Software applications (i.e., software resources) may refer to computer software that enables a computing device to perform tasks. In some examples, software applications may be referred to as "applications," "apps," or "programs." Example applications include, but are not limited to, system diagnostic applications, system management applications, system maintenance applications, word processing applications, spreadsheet applications, messaging applications, media streaming applications, social networking applications, and gaming applications.

[0042] Non-transitory memory can be a physical device used to temporarily or permanently store programs (e.g., instruction sequences) or data (e.g., program state information) for use by a computing device. Non-transitory memory can be volatile and / or non-volatile addressable semiconductor memory. Examples of non-volatile memory include, but are not limited to, flash memory and read-only memory (ROM) / programmable read-only memory (PROM) / erasable programmable read-only memory (EPROM) / electrically erasable programmable read-only memory (EEPROM) (e.g., commonly used for firmware, such as bootloaders). Examples of volatile memory include, but are not limited to, random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), phase change memory (PCM), and disk or tape.

[0043] These computer programs (also referred to as programs, software, software applications, or code) include machine instructions for a programmable processor and may be implemented in high-level procedural and / or object-oriented programming languages ​​and / or assembly / machine languages. As used herein, the terms "machine-readable medium" and "computer-readable medium" refer to any computer program product, non-transitory computer-readable medium, apparatus, and / or device (e.g., disk, optical disk, memory, programmable logic device (PLD)) for providing machine instructions and / or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term "machine-readable signal" refers to any signal for providing machine instructions and / or data to a programmable processor.

[0044] Various implementations of the systems and techniques described herein can be realized in digital electronic and / or optical circuits, integrated circuits, specially designed ASICs (application specific integrated circuits), computer hardware, firmware, software, and / or combinations thereof. These various implementations may include implementations in one or more computer programs executable and / or interpretable on a programmable system comprising at least one programmable processor, which may be special purpose or general purpose, coupled to receive data and instructions from a storage system, and to send data and instructions to the storage system.

[0045] The processes and logic flows described in this specification can be performed by one or more programmable processors, also known as data processing hardware, executing one or more computer programs to perform functions by operating on input data and generating outputs. These processes and logic flows can also be performed by dedicated logic circuits, such as FPGAs (field programmable gate arrays) or ASICs (application-specific integrated circuits). For example, processors suitable for executing computer programs include general-purpose and special-purpose microprocessors, and any one or more processors of any kind of digital computer. Typically, the processor will receive instructions and data from a read-only memory or a random access memory or both. The basic elements of a computer are a processor for executing instructions and one or more storage devices for storing instructions and data. Typically, a computer will also include or be operably connected to one or more large-capacity storage devices for storing data, such as magnetic disks, magneto-optical disks, or optical disks, to receive data from the large-capacity storage device or to transmit data to it, or both. However, a computer does not need to have such a device. Computer-readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media and storage devices, including, for example, semiconductor memory devices, such as EPROM, EEPROM and flash memory devices; magnetic disks, such as internal hard disks or removable disks; magneto-optical disks; and CD ROM and DVD-ROM disks. The processor and memory may be supplemented by or incorporated in special purpose logic circuitry.

[0046] To provide interaction with a user, one or more aspects of the present disclosure may be implemented on a computer having a display device for displaying information to the user, such as a CRT (cathode ray tube), LCD (liquid crystal display) monitor, or touch screen, and an optional keyboard and pointing device, such as a mouse or trackball, through which the user can provide input to the computer. Other types of devices may also be used to provide interaction with the user; for example, the feedback provided to the user may be any form of sensory feedback, such as visual feedback, auditory feedback, or tactile feedback; and input from the user may be received in any form, including sound, voice, or tactile input. In addition, the computer may interact with the user by sending documents to and receiving documents from a device used by the user; for example, by sending a web page to a web browser on a user's client device in response to a request received from the web browser.

[0047] A tool and method are provided for assembling a first workpiece to a second workpiece to form a subassembly, and assembling the subassembly to a support structure using a single downstroke. The tool and method clamp the first workpiece and automatically center the first workpiece relative to the support structure during the downstroke, and also center the subassembly relative to the support structure during the downstroke.

[0048] In addition, the tool and method can be configured to align the first workpiece and the second workpiece relative to each other before assembly with the support structure. In particular, the size of the tool accommodates the height difference between the first workpiece and the second workpiece to position the bottom of the first workpiece flush with the bottom of the second workpiece.

[0049] In addition, the tool is configured to hold the first workpiece in suspension. In such an aspect, the tool includes a clamp configured to move from a retracted state to an extended state, wherein in the extended state, the clamp is in tension fit engagement with the first workpiece. In one aspect, the clamp is moved from the retracted state to the extended state by movement of the ram along the axis.

[0050] refer to Figure 1 and 2 , an illustrative description of a main assembly 10 is provided. The main assembly 10 includes a first workpiece 12, a second workpiece 14, and a support structure 16. For illustrative purposes, the main assembly 10 is a transmission 200, or at least a portion of a transmission, and the first workpiece 12 is a bearing 202, the second workpiece 14 is a bearing support 204, and the support structure 16 is a pinion shaft 206. The bearing 202 assembled with the bearing support 204 forms a subassembly 26. It should be understood that the first workpiece 12, the second workpiece, and the support structure 16 can be implemented by other components without departing from the scope of the appended claims.

[0051] The first workpiece 12 is a cylindrical member having a bore extending through the cylindrical member, also referred to herein as the "first bore 18". In the case where the first workpiece 12 is a bearing 202, the first workpiece may include an inner race 20. In this case, an outer surface 22 of the first workpiece 12 is concentric with the inner race 20 and forms the outer periphery of the first workpiece 12.

[0052] The second workpiece 14 defines a cover for encapsulating components (not shown) of the transmission 200. The second workpiece 14 also includes an aperture extending through the body of the second workpiece 14, also referred to herein as the "second hole 24." In one configuration, the second hole 24 has a constant radius and is sized to slidably receive the first workpiece 12.

[0053] The first work piece 12 and the second work piece 14 are assembled together to form a subassembly 26. The subassembly 26 is then attached to the support structure 16 to form the main assembly 10. In one aspect, the first work piece 12 is configured to slide completely through the second hole 24. As such, the first work piece 12 must be positioned in the second work piece 14 in a manner that the first work piece 12 cannot be pushed through the second work piece 14.

[0054] The support structure 16 includes a base 28 and a head 30 disposed on the base 28. The head 30 is configured to be disposed within the first hole 18 of the first workpiece 12. The head 30 is a generally cylindrical member and may include a through hole 32. The head 30 includes a lip 34 that defines a top of the head 30 and bounds the through hole 32. In one configuration, an inner surface 36 of the lip 34 may be inclined.

[0055] Reference now Figure 3 , the main assembly 10 is assembled at a workstation 38. The workstation 38 includes a base 40 and a tool 42 fixed to the bottom of the base 40. The tool 42 can be driven by a driver 44, which is operable to move the tool 42 along a fixed axis and in a first direction "1D" away from the bottom of the base 40. Figure 3 As shown, when the tool 42 moves in a direction downward or away from the base 40 during use, the first direction is referred to herein as the "down stroke". The actuator 44 can be any device currently known or later developed that is configured to exert a force on the actuator 44 to move the actuator 44 away from the base 40, such as a pneumatic pump, an electric motor, etc. Once the down stroke is completed, the tool 42 moves to the starting position "SP" (such as Fig.11 4 (shown) and is ready to perform another downstroke. The workstation 38 may include a controller 46 for controlling the operation of the tool 42. The controller 46 may be located within the base 40, or may be remote from the workstation 38 and coupled to the workstation 38 via a wired or wireless connection. It should be understood that the workstation 38 may include a known input (not shown) that provides manual control of the tool 42, such as a start button, a stop button, a manual control button, etc.

[0056] The tool 42 includes a housing 48 made of a generally durable and rigid material such as stainless steel. The housing 48 is generally a cylindrical member and includes a body 50, a neck 52, and a shoulder 54. The neck 52 is configured to press against the top surface 12a of the first workpiece 12, and the shoulder 54 is configured to press against the top surface 14a of the second workpiece (e.g., Figure 6-10 shown).

[0057] Reference now Figure 6 The housing 48 further includes a main bore 56 extending from a first end 50a in the body 50 to a distal end 52a of the neck 52. The outer diameter of the neck 52 is smaller than the outer diameter of the first workpiece 12. The shoulder 54 is a radial flange disposed between the body 50 and the neck 52. The diameter of the shoulder 54 is larger than the diameter of the body 50, the diameter of the neck 52, and the inner diameter of the second bore 24 of the second workpiece 14.

[0058] Refer again Figure 6 as well as Figure 4 and Figure 5, the tool 42 also includes a plunger 58. The plunger 58 is disposed in the main bore 56 of the housing 48. The plunger 58 is a generally cylindrical member having an inner bore 60 disposed on a first end 58a of the plunger 58 and closed by a second end 58b of the plunger 58. The diameter of the plunger 58 is smaller than the diameter of the main bore 56, which allows the plunger 58 to be slidably disposed in the main bore 56 of the housing 48. The plunger 58 is disposed in the main bore 56, and the second end 58b extends from the distal end 52a of the neck 52. The plunger 58 is configured to be biased in a first direction "1D" away from the shoulder 54.

[0059] The plunger 58 includes a clamp 62 that is configured to move from a retracted state to a deployed state. Figure 4 The clamp 62 is depicted in a retracted state, wherein the clamp 62 is substantially located within the inner bore 60 of the plunger 58 . Figure 5-9 The clamp 62 is shown in an expanded state. In the expanded state, the clamp 62 extends away from the outer surface of the plunger 58 to engage the inner surface of the first workpiece 12. In particular, the clamp 62 is configured to engage the first hole 18 of the first workpiece 12.

[0060] Refer again Figure 4 and 5 , now refer to Figure 6 , the plunger 58 can move between an extended position and a compressed position along a first direction 1D. In such an aspect, the tool 42 can include a first biasing element 64 disposed within the main bore 56. One end of the first biasing element 64 engages the first end 50a of the body 50, and the other end of the first biasing element 64 engages the first end 58a of the plunger 58. Any biasing element currently known or later developed can be modified for use herein, exemplarily including a spring, such as a coil spring. Therefore, by applying a load, the plunger 58 can move upward into the main bore 56 of the housing 48, thereby compressing the first biasing element 64. Once the load is removed, the first biasing element 64 is free to move the plunger 58 to the extended position.

[0061] The clamp 62 can be mechanically actuated to extend away from the outer surface of the plunger 58 in the deployed state and to reside substantially within the plunger 58 in the retracted state. In one aspect of mechanical actuation, the tool 42 includes a rod 66 disposed within the inner bore 60 of the plunger 58. The rod 66 is generally a cylindrical member having a solid body formed of a durable material such as steel. The rod 66 is configured to selectively engage the clamp 62 to move the clamp 62 from the retracted state to the deployed state. In such an aspect, the rod 66 is slidably disposed within the plunger 58. In one aspect, the rod 66 extends through the main bore 56 of the housing 48 to allow the rod 66 to have enough space to pass over the clamp 62. The rod 66 can be slid by a drive mechanism such as a pneumatic pump (not shown), which can be controlled by the controller 46.

[0062] The clamp 62 is configured to grasp the first workpiece 12 by creating a tension fit engagement with the inner surface of the first workpiece 12. In particular, the clamp 62 is configured to create a tension fit engagement with the first hole 18 of the first workpiece 12. It should be understood that the tension fit engagement is sufficient to hold the first workpiece 12 in suspension. The clamp 62 is schematically shown as having three jaws 62a, each of which is configured to be radially extended relative to the inner hole 60 of the plunger 58, and each of the jaws 62a is equidistant from each other. The jaws 62a can be formed of an elastic material to facilitate engagement with the first workpiece 12. For example, the jaws 62a can be formed of polyurethane, polypropylene, polystyrene, etc.

[0063] In one aspect, the jaw 62a includes a sliding surface 68 disposed within the inner bore 60 of the plunger 58. The sliding surface 68 is inclined relative to the longitudinal axis "A1" of the plunger 58. The sliding surface 68 can be at an angle between 20 and 70 degrees relative to the longitudinal axis "A1" of the plunger 58. In such an aspect, the working end 66a of the rod 66 can be rounded so as to slide against the sliding surface 68 of the jaw 62a, thereby displacing the jaw 62a outward to the deployed state. The plunger 58 can also include a second biasing element 70, which is disposed within the inner bore 60 and is configured to continuously push the jaw 62a into the retracted state. The second biasing element 70 can be a coil spring that connects each jaw 62a to each other, or a hinge spring that connects each jaw 62a to the plunger 58 and continuously pushes each jaw 62a to the retracted state.

[0064] Reference now Figure 6 , the tool 42 can be configured to center the subassembly 26 relative to the support structure 16. In one aspect, the second end 58b of the plunger 58 includes a bevel 72. The bevel 72 can be a rounded edge or a flat surface that is inclined relative to the longitudinal axis "A1" of the plunger 58. The bevel 72 is configured to engage the lip 34 of the head 30 of the support structure 16. The bevel 72 slides against the inner surface 36 of the lip 34 and centers the plunger 58 relative to the head 30.

[0065] The tool 42 is configured to hold the first workpiece 12 during the downstroke and insert the first workpiece 12 into the second hole 24 of the second workpiece 14. In such an aspect, the outer diameter of the plunger 58 is smaller than the inner diameter of the second hole 24 of the support structure 16. In addition, the outer diameter of the first workpiece 12 is slightly smaller than the second hole 24 of the second workpiece 14 to accommodate the first workpiece 12 within the second hole 24 of the second workpiece 14.

[0066] The first workpiece 12 has a first height "H1" and the second workpiece 14 has a second height "H2" greater than the first height "H1". The bottom surface 54a of the shoulder 54 is generally planar and defines an engagement surface that is operable to engage an outer surface of the second workpiece 14 that is adjacent to the second hole 24 of the second workpiece 14. In particular, the bottom surface 54a of the shoulder 54 is configured to press against the top surface 14a of the second workpiece 14 that is concentric with the second hole 24.

[0067] In one configuration, the first workpiece 12 is a bearing 202, the second workpiece 14 is a bearing support 204, and the support structure 16 is a pinion shaft 206. In this configuration, the bearing 202 includes an inner race 20 having an outer diameter that is smaller than the outer diameter of the neck 52. In addition, the distal end 52a of the neck 52 is generally planar and defines a bottom surface that is spaced apart from the bottom surface 54a of the shoulder 54 by a distance that is generally equal to the height difference between the bearing support 204 and the bearing 202. Thus, during the downstroke, the plunger 58 clamps the bearing 202 in a manner that presses the neck 52 against the top surface of the bearing 202.

[0068] As the tool 42 continues its downward stroke, the tool 42 centers the bearing 202 relative to the pinion shaft 206 by engaging the ramp 72 of the plunger 58 with the inclined inner surface 36 of the lip 34. Continuing the downward stroke, the neck 52 presses against the top surface of the bearing 202, pressing the bearing 202 into the second hole 24 of the bearing support 204. The housing 48 then advances along the downward stroke, and the shoulder 54 engages the top surface of the bearing support 204, at which point the bottom surface of the bearing support 204 and the bearing 202 are flush with each other and the subassembly 26 is formed.

[0069] Continuing the downstroke, the shoulder 54 and neck 52 of the housing 48 move the subassembly 26 as a whole toward the head 30 of the pinion shaft 206 and press the first hole 18 of the bearing 202 of the subassembly 26 onto the head 30. When the lip 34 of the head 30 of the pinion shaft 206 abuts the clamp 62, the controller 46 retracts the clamp 62 to the retracted position and the head 30 of the pinion shaft 206 slides into the first hole 18 of the bearing 202 to complete the main assembly 10. Thus, the tool 42 assembles the transmission 200 using a single stroke. In addition, during the downstroke, the tool 42 aligns the bearing 202 relative to the bearing support 204 and centers the subassembly 26 relative to the pinion shaft 206.

[0070] Reference now Fig.12, a method 100 for attaching a first workpiece 12 and a second workpiece 14 together and to a support structure 16 using a single stroke is described. At frame 102, the method 100 includes moving a tool 42 in a first direction 1D toward the first workpiece 12, the tool 42 having a body 50, a neck 52, a shoulder 54, and a plunger 58 slidably disposed within the body 50. The method 100 proceeds to frame 104, where the distal end 52a of the neck 52 engages the top surface 12a of the first workpiece 12 as the tool 42 moves in the first direction. The method 100 proceeds to frame 106, where the plunger 58 extends into the first hole 18 of the first workpiece 12.

[0071] At frame 108, the clamp 62 of the plunger 58 is moved from the retracted state to the extended state to engage the inner surface of the first hole 18 of the first workpiece 12. At frame 110, the tool 42 is moved in the first direction toward the second workpiece 14 to engage the shoulder 54 with the outer surface of the second workpiece 14, which is adjacent to the second hole 24 of the second workpiece 14. At frame 112, as the tool 42 moves in the first direction, the first workpiece 12 is pressed into the second hole 24 of the second workpiece 14 to form the subassembly 26. At frame 114, as the tool 42 continues to move in the first direction, the subassembly 26 is pressed onto the support structure 16.

[0072] The plunger 58 can be biased in a direction away from the housing 48. In such an aspect, the plunger 58 includes a first biasing element 64 located within a main bore 64 of the body 50 between the first end 50a of the body 50 and the first end 58a of the plunger 58. The first biasing element 64 can be a coil spring within a bore of the housing 48.

[0073] The method 100 may include centering the second workpiece 14 and the support structure 16 relative to each other. In particular, the second end 58a of the plunger 58 may include a bevel 72, and the support structure 16 may include a head 30 having a lip 34 defining a top of the head 30, the lip 34 including an inwardly inclined inner surface 36. The bevel 72 of the plunger 58 slides against the interior of the surface to center the plunger 58 relative to the head 30 of the support structure 16.

[0074] In one aspect, engaging the distal end 52a of the neck 52 with the top surface 12a of the first workpiece 12 includes holding the first workpiece 12 in suspension. In such an aspect, moving the clamp 62 of the plunger 58 from the retracted state to the extended state to engage the inner surface of the aperture of the first workpiece 12 includes engaging the first hole 18 of the first workpiece 12.

[0075] In one configuration, moving the clamp 62 of the plunger 58 from the retracted state to the extended state to engage the first hole 18 of the first workpiece 12 includes holding the first workpiece 12 in suspension. Thus, prior to assembly, the first workpiece 12 can be lifted above the second hole 24 of the second workpiece 14. In addition, the distance from the bottom surface 54a of the shoulder 54 to the distal end 52a of the neck 52 is substantially equal to the height of the second workpiece 14. Thus, the tool 42 aligns the bottom surface of the second workpiece 14 with the bottom surface of the first workpiece 12 and prevents the first workpiece 12 from being pushed past the second workpiece 14.

[0076] In one aspect of the method 100, the clamp 62 is mechanically moved from the retracted state to the deployed state. In such an aspect, the rod 66 is disposed within the plunger 58 and can be moved into contact with the clamp 62, thereby pushing the clamp 62 outward relative to the plunger 58 and into the deployed state. The rod 66 can be moved into contact with the clamp 62 by translating the rod 66 relative to and within the aperture defined by the plunger 58.

[0077] Reference now Figure 6-11 , describes the operation of the tool 42 and the method 100. The operation of the tool 42 is performed by the controller 46 as follows Figure 6-11 Execute in the order shown. Fig.11 The position of the tool 42 after the assembly of the main assembly 10 is completed is shown, wherein the tool 42 moves to the starting position "SP" after completing the down stroke.

[0078] Figure 6 The position of the tool 42 after initiating the downstroke is shown. The plunger 58 is disposed within the first hole 18 of the first workpiece 12. In particular, the controller 46 positions the plunger 58 so that the clamp 62 is disposed within the first hole 18. Figure 6 Also shown is a point in the operation of the tool 42 where the clamp 62 is in the deployed state and engages the first hole 18 of the first workpiece 12, holding the first workpiece 12 in suspension. To achieve this position, the controller 46 has moved the rod 66 downwardly along the inner bore 60 of the plunger 58, and the jaws 62a of the clamp 62 are moved to the deployed state as the rod 66 presses against the sliding surface 68 of the jaws 62a.

[0079] Figure 7 The tool 42 is shown further along the downstroke. As the tool 42 moves further along the downstroke, the first workpiece 12 is held by the clamp 62. The first biasing element 64 is fully extended and the ramp 72 of the plunger 58 engages the lip 34 of the head 30 of the support structure 16. Figure 7 It shows a situation where the first workpiece 12 is not aligned with the second workpiece 14. In particular, the first workpiece 12 is offset from the center of the second hole 24 of the second workpiece 14.

[0080] Figure 8The tool 42 is shown relative to Figure 7 Further along the downstroke, the ramp 72 of the plunger 58 has slid along the inclined inner surface 36 of the lip 34, and the ramp 72 is nested within the lip 34 of the head 30. In this way, the plunger 58 aligns the tool 42 and the first workpiece 12 with the second hole 24 of the second workpiece 14.

[0081] Fig. 9 The tool 42 is shown relative to Figure 8 The bottom surface of the neck 52 presses against the top surface of the first workpiece 12, pushing the first workpiece 12 into the second hole 24 of the second workpiece 14. As the tool 42 advances along the downstroke, the bottom surface 54a of the shoulder 54 engages the top surface 14a of the second workpiece 14. The plunger 58 is blocked by the head 30 of the support structure 16, causing the first biasing element 64 to move relative to the first workpiece 12. Figure 8 The position of the first biasing element 64 is shown compressed.

[0082] Fig. 9 Also shown is a gap formed between the top surface 12a of the first work piece 12 and the bottom surface 54a of the shoulder 54. The height of the gap is generally the same as the height difference between the first work piece 12 and the second work piece 14. Thus, when the shoulder 54 engages the second work piece 14, the bottom surface 14b of the second work piece 14 is flush or substantially coplanar with the bottom surface 12b of the first work piece 12. Fig. 9 It also shows how the plunger 58 is centered relative to the lip 34 of the head 30 so that the head 30 of the support structure 16 is aligned with the first hole 18 of the first workpiece 12 .

[0083] Fig.10 The tool 42 is shown relative to Fig. 9 As the tool 42 is further pressed, the first biasing element 64 moves relative to the Fig. 9 The position of the first biasing element 64 is shown to be further compressed. The controller 46 is operable to move the rod 66 upward to move the clamp 62 from the deployed state to the retracted state. For example, when the rod 66 passes over the sliding surface 68 of the clamp 62a, the second biasing element 70 is free to push the corresponding clamp 62a to the retracted state. At the same time, the tool 42 advances along the downstroke and the head 30 of the support structure 16 is free to insert into the first hole 18 of the first workpiece 12 to form the main assembly 10. The sequence of operations is controlled by the controller 46, which can time the movement of the clamp 62 into the retracted state as the head 30 is inserted into the first hole 18 of the first workpiece 12 to ensure that the head 30 is fully located in the first hole 18 before the clamp 62 releases the first workpiece 12.

[0084] Fig.11The assembled master assembly 10 and the tool 42 moved to the starting position "SP" are shown. It should be understood that the tool 42 can remain in a stationary position, in which case the master assembly 10 is transferred to another workstation for further assembly, and another first workpiece 12, second workpiece 14 and support structure 16 are moved to the tool 42 for assembly. However, those skilled in the art will appreciate that the tool 42 can be moved within the workstation 38, such as by a robotic arm, where multiple first workpieces 12, second workpieces 14 and support structures 16 are arranged for assembly.

[0085] Thus, a tool 42 and method 100 for assembling a primary assembly 10 at a single workstation 38 and a single downstroke are provided. In addition, the tool 42 and method 100 include clamping the first workpiece 12 during the downstroke and automatically centering the first workpiece 12 relative to the support structure 16. In addition, the tool 42 and method 100 can align the first workpiece 12 and the second workpiece 14 relative to each other prior to assembly with the support structure 16. The tool 42 and method 100 disclosed herein reduce the number of workstations, components, and steps required to assemble the primary assembly 10 relative to current practice.

[0086] Many embodiments have been described. However, it should be understood that various modifications can be made without departing from the spirit and scope of the present disclosure. Therefore, other embodiments are also within the scope of the following claims.

[0087] The foregoing description has been provided for the purpose of illustration and description. It is not intended to be exhaustive or to limit the present disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but where applicable, they are interchangeable and can be used in a selected configuration even if not specifically shown or described. This can also be varied in a variety of ways. Such variations should not be considered a departure from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims

1. A tool for attaching a first workpiece and a second workpiece to each other and to a support structure, the tool comprising: a housing including a body; a neck extending from the body and having an outer diameter substantially equal to an outer diameter of the first workpiece; a shoulder disposed between the body and the neck and having an outer diameter greater than the outer diameter of the body and the inner diameter of the aperture formed in the second workpiece; and a bore extending from a first end in the body to a distal end of the neck, and A plunger having a first end disposed within the bore and a second end extending from a distal end of the neck, the plunger being biased in a first direction away from the shoulder and including a clamp operable to extend away from an outer surface of the plunger in a deployed state to engage an inner surface of a first workpiece.

2. The tool of claim 1, further comprising a biasing element disposed within the bore, the biasing element engaging the first end of the bore and the first end of the plunger.

3. The tool according to claim 2, wherein: The biasing element is a spring.

4. The tool according to claim 3, wherein: The spring is a coil spring.

5. The tool of claim 1, further comprising a rod disposed within the plunger, the rod operable to selectively engage the clamp to move the clamp from a retracted state to a deployed state.

6. The tool according to claim 5, wherein: The rod is slidably disposed within the plunger.

7. The tool according to claim 1, wherein: The second end of the plunger includes a beveled surface.

8. The tool according to claim 1, wherein: The outer diameter of the plunger is smaller than the inner diameter of the support structure.

9. The tool according to claim 1, wherein: The shoulder defines an engagement surface operable to engage an outer surface of the second workpiece proximate the aperture of the second workpiece.

10. The tool according to claim 1, wherein: The first workpiece is a bearing having an inner ring having an outer diameter substantially equal to the outer diameter of the neck.

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