Vehicle Door Hinge Mounting Jig for Multi-Model Assembly
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Solution Overview
Problem
Conventional door hinge mounting jigs require multiple cylinder devices to accommodate different vehicle types, leading to increased weight, volume, and costs, making it difficult to simultaneously mount door hinges on both upper and lower pillars efficiently.
Innovation Solution
A system with a jig frame that reciprocates in the vehicle width direction, featuring a rotation index and vertical polyhedron-shaped rotation shaft, paired with clamping units and a bezel fixing unit, which allows for flexible mounting of door hinges on various vehicle types using a servomotor and driving cylinders, reducing the need for multiple jigs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple cylinder devices are used to clamp door hinges for different vehicle types, then adaptability to multiple vehicle types is improved, but weight and volume of the mounting jig increase
Solution Approach 1:
The mounting jig is designed with a universal clamping mechanism that can accommodate multiple vehicle types and door hinge configurations using a single device. The system employs adjustable clamping units with movable blocks and tooling pins that can be repositioned to match different mounting requirements, eliminating the need for multiple specialized jigs for different vehicle models.
Solution Approach 2:
The mounting jig incorporates dynamic elements including movable blocks that can slide along guide rails, adjustable clamping arms, and repositionable tooling pins. These dynamic components allow the jig to adapt its configuration for different door hinge types and vehicle models, providing versatility without requiring multiple fixed-purpose devices, thereby reducing overall weight and volume.
2Adaptability or versatility
If multiple cylinder devices are used to simultaneously clamp door hinges, then adaptability is improved, but volume of the mounting jig increases
Solution Approach 1:
The mounting jig employs a nested structure where tooling pins are inserted into movable blocks, which in turn are positioned within the main jig body. The clamping mechanism features nested components where adjustable arms fold into the jig frame when not in use. This nesting arrangement maximizes space utilization and reduces the overall volume required for the mounting equipment while maintaining adaptability to multiple vehicle types.
3Ease of operation
If separate processes are used to mount door hinges at upper and lower pillars, then ease of operation is improved, but productivity decreases
Solution Approach 1:
The mounting jig combines multiple clamping units for upper and lower door hinge mounting into a single integrated device. The jig simultaneously clamps both upper and lower door hinges using coordinated movable blocks and tooling pins, allowing both mounting operations to be performed in one positioning action. This merging of operations maintains ease of operation while significantly improving productivity by eliminating sequential separate processes.
Data Source
AI summary
A system for mounting a door hinge to upper and lower mounting portions of front and rear pillars of a vehicle body being transferred along a vehicle transfer line. The system includes: a jig frame installed to reciprocate in a vehicle width direction through a driving unit on a base frame outside the vehicle transfer line; a rotation index installed on the jig frame and rotatable by a predetermined angle through a servomotor; a vertical rotation shaft formed as a polyhedron having a cavity and coaxially connected to a rotation center axis of the rotation index along an up and down vertical direction; and a pair of clamping units installed through a mounting plate to a base plate fixed to each side of the vertical rotation shaft, the pair of clamping units being disposed at upper and lower portions of the mounting plate and configured to clamp the door hinge.