Adjustable Clamshell Fixture With Interchangeable Squeezers
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Solution Overview
Problem
Existing assembly fixtures for automotive clamshell components are custom-built and not reusable, leading to high tooling costs, lost production time, and space inefficiencies due to the need for multiple machines to accommodate varying component sizes and shapes.
Innovation Solution
A system with interchangeable squeezer units and an adjustable support assembly that allows for the formation of multiple clamshell component types by reconfiguring the locator members and replacing squeezer units, enabling efficient production of different clamshell components without the need for dedicated tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom-built strongback machines are used for each clamshell component type, then manufacturing precision and reliability are improved, but device complexity and capital costs increase
Solution Approach 1:
The strongback machine is designed with universal features including interchangeable squeezer units with different contacting surfaces, adjustable locator members that can be repositioned along guide ways, and a common frame structure. This allows a single machine to accommodate multiple clamshell component types while maintaining manufacturing precision through proper positioning and squeezing for each specific component.
2Productivity
If multiple dedicated strongback machines are maintained for different component types, then productivity is improved, but loss of time during machine switching increases
Solution Approach 1:
The locator members are designed to be dynamically adjustable along the guide ways of the frame, allowing quick repositioning between different component types. The squeezer units can be interchanged without replacing the entire machine, enabling rapid adaptation to different production requirements while maintaining high productivity.
3Adaptability or versatility
If multiple strongback machines are stored for different component types, then adaptability is improved, but use of space increases
Solution Approach 1:
A single strongback machine with universal features replaces multiple dedicated machines. The interchangeable squeezer units and adjustable locator members enable the same machine to produce different clamshell component types, dramatically reducing the number of machines needed and the associated floor space requirements while maintaining full adaptability.
4Manufacturing precision
If custom tools are purchased for each clamshell component, then manufacturing precision is improved, but capital costs increase
Solution Approach 1:
The tooling system is segmented into modular components: a common frame structure, interchangeable squeezer units, and adjustable locator members. This segmentation allows the expensive custom tooling features to be isolated to only the squeezer units and locator positions that need to be specific to each component type, while sharing the expensive frame and base structure across all component types, reducing overall capital costs.
Data Source
AI summary
A system for forming different types of clamshell components including a moveable base, a stationary base, and a squeezer assembly capable of accommodating different types of clamshell components having different lengths, shapes, locations of piercings. The squeezer assembly includes interchangeable squeezer elements. To switch between forming a first type of clamshell component and a second type of clamshell component, one of the two bases is moved relative to the other of the two bases and/or squeezer units for forming the first type of clamshell component are replaced with squeezer units for forming the second type of clamshell component. Reconfiguring the bases and interchanging the squeezers of a clamshell tool, instead of replacing an entire clamshell tool with a different clamshell tool, minimizes lost productivity time, reduces capital costs, and eliminates the problem of storing several different clamshell assembly tools.