Floating Joint Manufacturing Method for Precision Gap Control
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Solution Overview
Problem
Existing floating joints face challenges in efficiently assembling members with a predetermined clearance and preventing them from falling off, while maintaining smooth operation and misalignment absorption between actuators and driven bodies.
Innovation Solution
A method of manufacturing a floating joint involving a housing step, a caulking step, and a gap adjusting step, where a first and second connecting portion are swingable relative to each other, with a holding member and stopper member configuration, and using a caulking tool for both steps to ensure secure assembly and precise gap adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a slight gap is required between members to allow smooth tilting of the stud portion, then the ease of operation is improved, but the reliability of preventing members from coming off deteriorates
Solution Approach 1:
The stopper member acts as an intermediary element that provides both the necessary gap for smooth tilting operation and the securing function to prevent members from coming off. It is disposed between the first and second connecting portions, with a gap to the holding member that allows movement while the protrusion fits into the recess to prevent complete disengagement.
2Reliability
If strong pressing of members is applied to prevent falling off, then the reliability is improved, but the ease of operation deteriorates due to restricted swinging motion
Solution Approach 1:
The stopper member has different functional zones: a gap region that allows free swinging motion for ease of operation, and a protrusion-recess engagement region that provides securing force to prevent falling off. This local differentiation of functional properties resolves the contradiction between reliability and ease of operation.
3Manufacturing precision
If multiple separate tools are used for caulking and gap adjustment, then the manufacturing precision is improved, but the productivity deteriorates
Solution Approach 1:
The caulking tool is designed to perform both caulking and gap adjustment functions in a single operation. The tool includes a pressing portion for caulking and a gap adjustment portion that can adjust the gap between the stopper member and holding member, combining multiple functions into one tool to improve productivity while maintaining precision.
Solution Approach 2:
The caulking tool is designed as a multi-functional tool that can perform caulking, gap adjustment, and securing of members in sequence without requiring tool changes. This universal design improves manufacturing efficiency while maintaining the precision needed for proper gap adjustment.
Data Source
AI summary
A floating joint has a first connection section and a second connection section, which are capable of pivoting relative to each other. In the manufacturing of this joint, a receiving step is performed, in which the flange section of the first connection section, the umbrella section of the second connection section, a ring, and a plate are received within a case. Further, the following steps are performed: a staking step in which an end of the case is staked inward to cover the plate; and a gap adjustment step in which the plate is pressed toward the ring to adjust the gap between the ring and the plate.