Adaptive Spring Compression Tool for Vehicle Suspension Alignment
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Solution Overview
Problem
Conventional tooling systems in automobile manufacturing are obsolete when new vehicle models or design modifications are introduced, requiring new dimensions and configurations that are not easily accommodated. Additionally, these systems face challenges when the vehicle body structure is insufficient to facilitate simple spring compression.
Innovation Solution
An adaptive spring compression tool that can be modified and programmed to accommodate various vehicle models, products, and design modifications without replacing the entire tool system. The tool includes a frame, a spring clamping unit, a moveable frame, supports, and a control system that adjusts the spring height in real-time to achieve a desired alignment and compression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conventional tooling systems use fixed components on a base plate, then the system provides stable alignment, but the system becomes obsolete when new vehicle models or design modifications are introduced
Solution Approach 1:
The base plate is transformed from a static fixed structure to a dynamic adjustable platform. Motorized actuators enable the base plate to move and reposition tool components automatically, allowing the same hardware to adapt to different vehicle models and spring configurations without becoming obsolete.
Solution Approach 2:
The system changes operational parameters through programmable control. The base plate position, tool component locations, and compression forces are adjusted by modifying control parameters in the programmable logic controller, enabling the same physical system to handle various vehicle designs by changing software parameters rather than hardware configurations.
2Adaptability or versatility
If conventional tooling systems require new dimensions and configurations for new vehicle models, then the system can accommodate design changes, but the entire tool system must be replaced
Solution Approach 1:
The base plate serves multiple functions across different vehicle models. By making the base plate adjustable and programmable, a single universal base plate can accommodate various spring sizes, vehicle configurations, and assembly requirements, eliminating the need to manufacture and install entirely new tool systems for each design change.
Solution Approach 2:
The system incorporates motorized adjustment mechanisms that allow the base plate and tool components to dynamically reconfigure for different vehicle models. This dynamic capability enables one tool system to handle multiple designs without physical replacement.
3Reliability
If the vehicle body structure is not sufficient to facilitate simple spring compression, then a specialized tool is required, but the tool must be tailored to each given spring design
Solution Approach 1:
The system replaces manual mechanical adjustment with motorized actuation and programmable control. Motors and sensors automatically position the base plate and apply appropriate compression forces, eliminating the need for mechanically customizing each tool for different spring designs. The programmable logic controller adapts the mechanical action to match various spring specifications.
Solution Approach 2:
The system adjusts compression parameters (force, position, speed) programmatically based on the specific spring design. By changing control parameters rather than physical tool characteristics, the same specialized tool can reliably compress different spring types without requiring physical customization for each design.
4Manufacturing precision
If the spring compression tool adjusts spring height in real-time, then the desired spring height and alignment are achieved, but the control system complexity increases
Solution Approach 1:
The system incorporates sensors that provide real-time feedback on spring position and base plate location. This feedback loop allows the programmable logic controller to automatically adjust motor actuation to achieve precise spring height and alignment, managing control complexity through automated closed-loop control rather than complex mechanical linkages.
Solution Approach 2:
Complex mechanical adjustment mechanisms are replaced with motorized actuation controlled by programmable logic. The control complexity is managed through software algorithms rather than complex mechanical gear systems, enabling precise real-time adjustment with cleaner system architecture.
Data Source
AI summary
The present disclosure describes an adaptive spring compression tool that streamlines and partially automates the joining of a vehicle suspension system with a vehicle body on an assembly line. The spring compression tool can be modified and programmed to accommodate various vehicle models, products, and design modifications without replacing the entire tooling system. Additionally, the spring compression tool of the present disclosure has a structure, a function, and an operation that facilitates the compression of a spring without exerting large forces on the vehicle body. In various embodiments, the spring compression tool comprises at least two independent drives that adjust the compression of a spring and the position of a suspension system to achieve a car line position with the vehicle body.