Horizontal Clevis Insertion for Hinge Assembly Lines

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Solution Overview

Problem

Automated hinge assembly lines face inefficiencies in inserting 'J' shaped clevises, requiring multiple operations and rotations, and are not easily adaptable to different component sizes and types, with maintenance challenges.

Innovation Solution

A station and method that aligns the clevis insertion along a horizontal direction using a vibrating channel, manipulator, insertion actuator, positioning unit, centring unit, and guide rod, allowing for efficient insertion without assembly reorientation, with a modular design for adaptability and easy maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If clevises are inserted along a vertical direction from top downwards, then the insertion operation can be performed, but the assembly must be rotated by 180° between two insertions, increasing operation time and complexity

Engineering Contradiction:

Improveinsertion operationVSAvoidassembly rotation time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent inverts the conventional vertical insertion direction and implements horizontal insertion instead. The manipulator positions the clevis horizontally and inserts it along the horizontal axis, eliminating the need for assembly rotation between insertions of opposing clevises.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the insertion dimension from vertical (one-dimensional vertical movement) to horizontal (one-dimensional horizontal movement). This dimensional change allows simultaneous access to opposing clevis positions without requiring assembly rotation, thereby reducing operation time.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of manufacture

If a fixed design is used for the insertion station, then manufacturing is simpler, but adaptability to different component sizes and types is reduced

Engineering Contradiction:

Improvestation manufacturingVSAvoidcomponent adaptability

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The patent implements adjustable and reconfigurable components in the insertion station, including adjustable manipulators, reconfigurable positioning units, and adaptable centring mechanisms. These dynamic elements allow the station to accommodate different component sizes and types while maintaining ease of manufacture through modular design.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The insertion station is designed with universal components that can perform multiple functions. The manipulator system, positioning unit, and centring mechanism are configured to handle various clevis and component combinations, making the station versatile without requiring complete redesign for each application.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Force

If pneumatic firing systems are used for clevis insertion, then insertion force can be achieved, but energy consumption increases and continuous operation is disrupted

Engineering Contradiction:

Improveinsertion forceVSAvoidenergy consumption

Core Design Contradiction:

ForceVSUse of energy by moving object

Solution Approach 1:

The patent replaces the pneumatic firing system with a mechanical insertion system. The manipulator uses controlled mechanical motion to position and insert the clevis, with force applied through the insertion actuator. This substitution eliminates the need for pneumatic energy while maintaining sufficient insertion force and enabling continuous operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution reduces assembly line operations, enables efficient insertion of clevises without reorienting the assembly, and allows for easy configuration and maintenance, achieving energy savings by eliminating pneumatic firing systems and enabling continuous operation with pre-configured transport systems.

Implementation Method 1

a vibrating channel (14) suitable to order loose components coming from a component feed hopper (80) along a row

Methodology Applied

Scientific EffectVibration: Vibration

Data Source

PatentUS11260479B2Station and method for inserting a component in an assembly to be assembled

Publication Date: 2022.03.01 COSBERG

AI summary

An insertion station of a component (2), for example a clevis, in a component seat (12) formed in an assembly (3) to be assembled, for example a hinge assembly for doors, includes a component ordering device (14) to order the loose components coming from a component feed hopper. A component support seat (16) receives the component and is configured in such a way as to guide the component in the horizontal insertion direction. A manipulator (20) picks a component (2) from the component ordering device (14) and deposit the component in the component support seat (16). An insertion actuator (30) has a pusher member (32) operable to push the component (2) in the component seat (12), and a positioning unit (40), including an abutment (42) operable to block the assembly (3) in a component insertion position.