Floating Fastener Insertion Tool for Self-Aligning Sheet Metal Assembly
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Solution Overview
Problem
Manual insertion of push-in fasteners into thin sheet metal workpieces is tedious, repetitive, and demanding, requiring complex automation solutions with customized fixtures and sensors that increase cycle time and maintenance costs.
Innovation Solution
An automated fastener insertion tool featuring a floating tool assembly with a locating pin and punch, which homes to a fixed structure, moves to a desired working position, and locks in place to accurately install push-in fasteners into workpieces, reducing misalignment and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual insertion method is used, then flexibility and simplicity are maintained, but productivity is low and labor intensity is high
Solution Approach 1:
The tool assembly is designed to float and move dynamically in response to workpiece position variations. The floating tool assembly includes a tool body that can laterally translate along guides when the workpiece is positioned, allowing the system to adapt to position variations without requiring complex sensors or programming while maintaining automated operation
Solution Approach 2:
The system uses the workpiece itself to drive the alignment process. When the workpiece is positioned, its features automatically engage with the floating tool assembly, causing the tool to self-align to the correct position through mechanical interaction rather than requiring external sensing or complex control algorithms
2Manufacturing precision
If customized fixture with sensors is used, then positioning accuracy is improved, but cycle time increases and maintenance complexity increases
Solution Approach 1:
The floating tool assembly is pre-configured with guides and alignment features that automatically engage with the workpiece when it is positioned. This preliminary mechanical arrangement ensures accurate alignment occurs passively during the normal positioning process, eliminating the need for additional sensing steps or programming that would extend cycle time
Solution Approach 2:
The invention extracts and eliminates the complex sensing and position adjustment feedback systems from the automated insertion tool. Instead, it relies on pure mechanical alignment through the floating tool assembly that responds naturally to workpiece position, thereby reducing maintenance complexity and cycle time while preserving positioning accuracy
3Reliability
If push-in fastener is misaligned, then workpiece damage occurs or assembly fails, but achieving precise alignment increases system complexity
Solution Approach 1:
The floating tool assembly can dynamically adjust its position laterally along guides in response to workpiece position variations. This mechanical flexibility ensures that even if the workpiece is not perfectly positioned, the tool will self-align to achieve proper fastener alignment, preventing misalignment damage without requiring complex alignment systems
Solution Approach 2:
The floating mechanism provides a mechanical cushion that absorbs position variations and misalignment tendencies before they can cause fastener misalignment or workpiece damage. The tool assembly has built-in compliance through its floating design that prevents hard impacts and misalignment failures
Data Source
AI summary
A method of installing a push-in fastener includes the steps homing a floating tool assembly to a home position, the floating tool assembly carries a locating pin and a punch, releasing the floating tool assembly, positioning a workpiece at a target position, retrieving a fastener with the punch, engaging the workpiece with the locating pin which causes the floating tool assembly to move to a desired working position with respect to the workpiece, locking the floating tool assembly in the desired working position, retracting the locating pin, and advancing the punch to install the fastener in the workpiece.