Adjustable Prewinder Assembly for Helical Coil Insert Installation
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Solution Overview
Problem
The installation of fine thread size helically coiled wire inserts is challenging due to their flexibility, requiring pre-winders and spacers or shims, which increases costs and time delays, as existing pre-winders often necessitate disassembly and multiple part stocking to achieve proper installation depth.
Innovation Solution
An adjustable pre-winder assembly that includes a rotatably disposed stop regulator with internal threads, allowing for infinitely adjustable axial displacement, and a mandrel with a pin that contacts a stop face to determine the insertion depth, eliminating the need for spacers and simplifying the installation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spacers or shims are used to accommodate differences in insert length or installation depth, then the installation depth precision is improved, but the device complexity increases and additional part costs are incurred
Solution Approach 1:
The prewinder assembly is designed with an adjustable mandrel position mechanism that can accommodate multiple insert lengths and installation depths without requiring different spacers or shims. The stop regulator allows the mandrel to be positioned at various depths, making a single prewinder assembly universal for different fine thread size inserts, thereby eliminating the need for multiple specialized parts.
Solution Approach 2:
The mandrel is made adjustable rather than fixed, allowing its position to be dynamically changed according to the specific insert length and required installation depth. The stop regulator mechanism enables continuous or incremental adjustment of the mandrel position, providing flexibility to adapt to different installation requirements without adding device complexity.
2Manufacturing precision
If spacers or shims are installed to achieve proper installation depth, then the manufacturing precision is improved, but the installation time increases due to disassembly and reassembly
Solution Approach 1:
The mandrel position is made dynamically adjustable through the stop regulator mechanism, allowing operators to quickly set the desired installation depth without disassembling the prewinder assembly. This eliminates the time-consuming process of removing and reinstalling spacers or shims for each different insert length or depth requirement.
Solution Approach 2:
The stop regulator is pre-configured with adjustment mechanisms that allow the mandrel position to be set in advance for different insert lengths and installation depths. This preliminary setup capability eliminates the need for time-consuming trial-and-error installations with different spacers during the actual installation process.
3Adaptability or versatility
If multiple sizes of spacers or shims are stocked to accommodate different insert lengths, then the adaptability is improved, but the inventory costs and part management complexity increase
Solution Approach 1:
The prewinder assembly with adjustable mandrel position serves as a universal tool that can handle multiple insert lengths and installation depth requirements. This single versatile device replaces the need to maintain inventory of multiple specialized spacers and shims, reducing both inventory quantity and part management complexity while maintaining full adaptability.
Solution Approach 2:
The functionality of multiple different spacers and shims is merged into a single adjustable prewinder assembly. The stop regulator mechanism combines the adjustment capabilities that would otherwise require multiple discrete parts, consolidating inventory needs while maintaining the ability to accommodate various insert specifications.
4Manufacturing precision
If the prewinder is disassembled and reassembled to install spacers or shims, then the installation depth precision is improved, but the productivity decreases due to repeated disassembly and testing
Solution Approach 1:
The adjustable mandrel position mechanism allows installation depth precision to be achieved through simple regulatory adjustments rather than repeated disassembly and reassembly. The stop regulator provides a quick-adjust mechanism that maintains precision while dramatically improving productivity by eliminating iterative tool disassembly and reassembly cycles.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adjustable pre-winder assembly enables precise and efficient installation of helically coiled inserts by allowing manual adjustment of the mandrel depth without disassembly, reducing costs and time delays associated with spacer usage and multiple part handling.
Implementation Method 1
A stop is threadably received within the stop regulator, the stop having a flange defining a stop face and a substantially tubular body extending from the flange having a plurality of external threads on the tubular body and a smooth wall internal aperture extending throughout a length of the stop member. The external threads are engageable with the internal threads of the stop regulator permitting infinitely adjustable axial displacement of the stop member along a length of the internal threads by manual rotation of the stop regulator.
Data Source
AI summary
A prewinder apparatus attached to a drive tool to install helical coil inserts includes an adapter attached to the drive tool. A rotatable tubular sleeve in the adapter is engaged with the tool drive and has opposed engagement walls of a longitudinal slot extending through a hollow portion. A mandrel has a threaded first end and a pin transversely extending from a second end positioned within the longitudinal slot. A stop slides within the adapter member and rotatably receives the sleeve. The stop has a plurality of external threads. A stop regulator rotatably disposed in the adapter member has internal threads engaged with the stop external threads. The stop is axially displaceable within the adapter member and infinitely positionable along the stop external threads by manually rotating the stop regulator. A ball or male detent member biased to engage detent cavities of the stop regulator provides predetermined stop axial displacement.