Fixture for Automotive Bumper Skin Punching and Bracket Fixing
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Solution Overview
Problem
The existing methods for mounting ultrasonic sensors or headlight washers on vehicle bumper skins require two separate operations: punching a hole and fixing the support, which are often performed on different stations, leading to difficulties in maintaining the correct geometric location of the hole during transfer, especially after painting, and result in increased costs and quality issues.
Innovation Solution
A tool with a punch, stripper, and die that allows for simultaneous or sequential punching and fixing of the support on the bumper skin without transferring the part between stations, using a support holder and ultrasonic welding or other fastening means to maintain the support's position and secure it to the skin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If punching and fixing operations are performed on separate stations, then each operation can be optimized independently, but the geometric location reference is lost during transfer and positioning accuracy deteriorates
Solution Approach 1:
The patent combines the punching operation and fixing operation into a single integrated station. The support holder is designed to hold the support in its final position relative to the skin, allowing both operations to be performed without transferring the part between stations, thereby maintaining geometric location reference and positioning accuracy.
Solution Approach 2:
The support holder acts as an intermediary device that bridges the punching and fixing operations. It holds the support in the correct final position relative to the skin during punching, ensuring that the geometric location reference is maintained without requiring separate positioning operations at different stations.
2Productivity
If punching and fixing are performed sequentially on separate stations, then each operation can be performed with dedicated tooling, but cycle time increases due to transfer operations
Solution Approach 1:
The patent merges the punching and fixing operations into a single station, eliminating the transfer time between stations and reducing overall cycle time. The integrated tooling performs both operations sequentially in one location, improving productivity despite requiring a more complex multi-functional tooling system.
3Measurement precision
If the support is fixed after punching on a separate station, then the operations can be optimized independently, but the geometric reference location is lost during transfer
Solution Approach 1:
The support holder is designed to pre-position the support in its final location relative to the skin before the punching operation begins. This preliminary positioning ensures that the geometric reference accuracy is maintained throughout the process, and eliminates the need for time-consuming transfer operations that would otherwise cause reference loss.
4Area of stationary object
If multiple separate operations are used for mounting equipment, then each operation can be performed with specialized tooling, but the surface area required for the machine increases
Solution Approach 1:
The patent consolidates multiple operations (punching and fixing) into a single station, reducing the machine surface area required. The integrated tooling performs both operations in one location, decreasing the overall footprint of the equipment while maintaining the ability to perform specialized operations with dedicated tooling components.
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
This approach improves positioning accuracy, reduces cycle time and surface usage, and prevents bumper skin deterioration, offering economic and quality benefits by maintaining geometric references and eliminating the need for repositioning, especially for painted bodywork parts.
Implementation Method 1
the means for fixing the support to the skin comprise an ultrasonic welding sonotrode and an anvil
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to tooling for securing an equipment bracket (8) on a plastics skin (13) of a motor vehicle bodywork component, the equipment being of the type that has to be held, by the bracket (8) secured to the skin (13), opposite an orifice formed for this purpose in said skin, the tooling comprising a punching element (6), a stripper (7) in which the punching element can slide and a die (2) into which the punching element can penetrate in order to cut the skin and form the orifice. It comprises a bracket holder (2), that is to say a member shaped to receive the bracket (8), which is fitted around said bracket holder (2), and to hold it, simply on account of this fitting, in its final position with respect to the skin (13); the die (2b) is an end of the bracket holder (2) opposite the punching element (6); the tooling comprises securing means (5, 7) for securing the bracket (8) to the skin (13) when it is fitted on the bracket holder (2). The invention also relates to a securing method and a bodywork component.