Connector Clamp Tool Change With Lifting and Centering Precision
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Solution Overview
Problem
Existing tool systems for fitting interior components with connector clamps are inflexible, requiring full replacement when components change, leading to high costs and production line downtime for maintenance or repairs, making it difficult to adapt to different vehicle components or production lines.
Innovation Solution
A tool system with a lifting and centering unit that allows tools to be quickly swapped, featuring a lifting floor for precise positioning and alignment, and a swap body vehicle for easy tool transfer, enabling rapid tool changes without interrupting production and facilitating the conversion of production lines to produce different components or vehicle lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the tool system is fully integrated into the production system for high positioning accuracy, then manufacturing precision is improved, but adaptability deteriorates as the entire system must be replaced when components change
Solution Approach 1:
The tool system is segmented into a fixed base unit and a replaceable tool module. The tool can be independently removed and replaced without replacing the entire production system, allowing high positioning accuracy through precise centering elements while enabling adaptability through tool interchangeability.
Solution Approach 2:
The tool is extracted as a separate, removable component from the production system. This allows the tool to be taken out for replacement or maintenance without affecting the base unit, resolving the contradiction between integrated precision and flexible adaptability.
2Reliability
If the tool system is fully integrated into the production system, then reliability is improved through stable operation, but ease of repair deteriorates as maintenance requires production line shutdown
Solution Approach 1:
The system is divided into a permanent base unit and a removable tool module. This segmentation allows the tool to be independently accessed for maintenance while the base unit remains stable and operational, improving both reliability and ease of repair.
Solution Approach 2:
The lifting elements are designed to automatically support the tool during replacement operations. This preliminary positioning action facilitates quick tool changes without requiring complex manual intervention or extended production shutdowns.
3Manufacturing precision
If the tool system is specially adapted to a specific interior component, then manufacturing precision is improved for that component, but adaptability deteriorates when production lines need to be converted
Solution Approach 1:
The base unit is designed as a universal platform that can accommodate different tool modules for various interior components. The standardized interface with centering elements allows the same base unit to support multiple specialized tools, achieving both precision for specific components and adaptability for production line conversion.
Solution Approach 2:
The system transitions from a static, fixed configuration to a dynamic, reconfigurable setup. The replaceable tool module allows the system to adapt its functionality dynamically based on production requirements while maintaining precise positioning through the centering mechanism.
4Adaptability or versatility
If the entire tool system is replaced when components change, then adaptability is improved for new components, but loss of time increases due to replacement duration
Solution Approach 1:
By segmenting the tool system into a permanent base and a removable tool module, only the necessary tool portion needs to be replaced rather than the entire system. This significantly reduces replacement time while maintaining full adaptability to different components.
Solution Approach 2:
The lifting elements are pre-positioned to automatically support the tool during replacement. This preliminary action streamlines the changeover process, allowing quick tool swaps without time-consuming manual positioning or system reconfiguration.
Data Source
AI summary
A tool system for fitting interior components, in particular dashboards or parts thereof, with connector clamps, includes a tool to hold an interior component in such a way that the interior component can be fitted with connector clamps. The tool system further includes a lifting and centering unit for holding the tool, and the lifting and centering unit includes lifting elements for lifting the tool from a working position into an alternating position and centering elements for centering the tool in the working position. The present disclosure also relates to a method for changing a tool of such a tool system.