Exhaust Sub-Assembly Jig for Universal Positioning
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Solution Overview
Problem
The existing manufacturing stations for motor vehicle exhaust lines are not efficiently adapted for producing sub-assemblies as spare parts, as they require costly and time-consuming modifications to positioning means, and the production of each sub-assembly is expensive due to the need for specific positioning tools.
Innovation Solution
A method and jig system that allows the reuse of manufacturing stations by delivering pre-assembled sub-assemblies with additional jig components that replace missing reference elements, enabling correct positioning without modifying the existing positioning means, using reusable templates with reinforced components and axial interlocking mechanisms for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the manufacturing station is modified to produce sub-assemblies individually, then sub-assembly production capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent makes the positioning means universal by enabling it to handle both complete assemblies and sub-assemblies through the use of reference elements that can be attached to different types of workpieces. The same positioning means can be used for producing complete exhaust line assemblies or individual sub-assemblies as spare parts, eliminating the need for separate positioning systems.
Solution Approach 2:
The patent introduces reference elements as intermediaries between the sub-assemblies and the positioning means. These reference elements are attached to the sub-assemblies and provide the necessary geometric references for positioning, allowing the existing positioning means to work with sub-assemblies without modification.
2Manufacturing precision
If new positioning means are designed for each sub-assembly, then positioning precision is improved, but manufacturing cost and time increase
Solution Approach 1:
Instead of designing unique positioning means for each sub-assembly type, the patent creates a universal positioning system that works with all sub-assemblies through standardized reference elements. This reference element can be attached to different sub-assemblies while providing consistent geometric references, maintaining positioning precision without requiring custom-designed positioning means for each variant.
3Adaptability or versatility
If the positioning means is adapted for sub-assemblies, then sub-assembly positioning is improved, but storage requirements and material costs increase
Solution Approach 1:
The patent employs a single universal reference element design that can be used across all sub-assembly production. This eliminates the need to manufacture and store multiple different positioning means for different sub-assembly types, reducing material consumption and storage requirements while maintaining full adaptability.
Solution Approach 2:
The reference elements are designed to be reusable across multiple sub-assembly productions. Instead of creating disposable or dedicated positioning means for each sub-assembly type, the same reference elements can be attached and removed repeatedly, reducing overall material consumption and waste.
Data Source
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AI summary
The invention concerns a method of discrete manufacturing of a sub-assembly (34) of elements of a motor vehicle exhaust line on a manufacturing station, characterised in that only the sub-assembly (34) is delivered pre-assembled to the manufacturing station, at least one jig (36) being previously mounted on the pre-assembled sub-assembly (34) in order to replace reference additional elements missing from the sub-assembly (34) in order to allow the sub-assembly (34) to be positioned correctly on the machining station without modifying the means (33) for positioning said station relative to a "complete" usage mode in which the station receives a complete assembly. The invention also proposes a jig for implementing the method.