Boom Assembly Arc-Linear Segmentation for Single-Die Manufacturing
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Solution Overview
Problem
The challenge in manufacturing boom assemblies for front loaders is the difficulty in forming round shapes with consistent radii of curvature for different lengths without requiring multiple press dies, which increases costs and reduces productivity due to the need for die changes and labor-intensive fabrication processes.
Innovation Solution
The boom assembly design features a front and rear sub-assembly with symmetric arc and linear upper surfaces, allowing for the use of a single press die to form arc portions with the same radius of curvature, while varying the length of linear portions to accommodate different lengths, thus minimizing die changes and labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple press dies are used to form boom sub assemblies with different lengths and same radius of curvature, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
A single press die is designed to form arc portions of boom sub assemblies with different lengths while maintaining the same radius of curvature. The press die forms only the arc portion with consistent radius, while the linear portion length is varied to achieve different boom lengths, making one press die universal for multiple product variants.
Solution Approach 2:
The boom sub assembly is segmented into two distinct portions: an arc portion with consistent radius of curvature formed by the press die, and a linear portion whose length can be varied. This segmentation allows the arc portion to be standardized while the linear portion provides length variation, enabling single-die manufacturing of multiple lengths.
2Manufacturing precision
If multiple press dies are used to form boom sub assemblies with different lengths, then manufacturing precision is improved, but productivity decreases due to die changing steps
Solution Approach 1:
The press die is designed as a universal tool that can form arc portions for boom sub assemblies of different lengths without requiring die changes. The same press die produces consistent arc portions across all variants, eliminating downtime associated with die changing while maintaining manufacturing precision.
3Ease of manufacture
If arc portions with same radius of curvature are used for different lengths, then ease of manufacture is improved, but adaptability decreases due to interference with hydraulic cylinder
Solution Approach 1:
The boom sub assembly is divided into an arc portion with fixed radius of curvature (formed by press die) and a linear portion with variable length. This segmentation enables easy manufacturing with a single press die while accommodating different total lengths by adjusting only the linear portion, avoiding hydraulic cylinder interference.
Solution Approach 2:
Different portions of the boom sub assembly have different characteristics: the arc portion has consistent radius of curvature for manufacturing efficiency, while the linear portion has variable length for adaptability to different applications and clearance requirements. This local differentiation resolves the contradiction between ease of manufacture and adaptability.
Data Source
AI summary
There is provided a boom assembly bent at the center in a longitudinal direction so as to form a round shape protruding upward when seen from the side, comprising; a front boom sub assembly (47), the front boom sub assembly constituting the front of the center in the longitudinal direction of said boom assembly; and a rear boom sub assembly (48), the rear boom sub assembly constituting the rear of the center in the longitudinal direction of the boom assembly, wherein the front boom sub assembly (47) and the rear boom sub assembly (48) are symmetric when seen from the side, and portions from the midway positions in the longitudinal direction of the front boom sub assembly (47) and the rear boom sub assembly (48) to the center in the longitudinal direction of the boom assembly (12) have upper surfaces of arc shape protruding upward when seen from the side, and portions from the middles in the longitudinal direction of the front boom sub assembly (47) and the rear boom sub assembly (48) to ends in the longitudinal direction of the boom assembly (12) have upper surfaces of linear shape when seen from the side.