Active Grille Shutter In-Tool Assembly With Automated Testing
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Solution Overview
Problem
Current active grille shutter designs require multiple steps, transportation, and manual assembly of components, which is inefficient and prone to errors.
Innovation Solution
A process that utilizes specific tooling features and component designs to enable the injection molding and automatic assembly of active grille shutter components within the same injection mold tool, allowing for complete assembly and automated testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If components are manufactured separately and assembled manually at different locations, then manufacturing flexibility is maintained, but assembly time and labor costs increase
Solution Approach 1:
The patent combines the injection molding process and assembly process into a single integrated operation. The mold includes movable cavities that form components and simultaneously assemble them into the final grille assembly as the mold opens, eliminating separate assembly steps and significantly improving productivity
Solution Approach 2:
The injection mold serves multiple functions: it forms individual components through injection molding, positions components for assembly, and performs the assembly operation itself. The movable cavities transform from单纯的成型 cavity to dual-purpose tools that both create and assemble components
2Loss of time
If multiple transportation and storage steps are used for component assembly, then manufacturing flexibility is maintained, but production time and costs increase
Solution Approach 1:
Components are pre-formed within the mold cavities during the injection molding process itself, and the mold design pre-positions all components in their final assembled locations. When the mold opens, components are already in place and ready for assembly, eliminating the need for separate transportation and storage steps
3Reliability
If manual assembly is used for active grille shutter components, then assembly flexibility is maintained, but error rates and labor costs increase
Solution Approach 1:
The injection mold performs the assembly operation automatically through its own mechanical movement. As the mold opens, the movable cavities automatically position and assemble the components into the final configuration without requiring manual intervention, ensuring consistent accuracy and enabling full automation
Data Source
AI summary
A method of in tool formation and assembly of an active grille shutter system, followed by an automated testing process. The method includes providing a tool having a plurality of sliders that assist in the formation and assembly of the active grille shutter system. The components of the active grille shutter system are individually formed in a single tool, with each of the components being spaced apart from each other. After formation of the components a number of sliders and an end of arm tool push the components together to form the assembled active grille shutter system. The end of arm tool then takes the assembled active grille shutter system to a testing station where the operation is checked.