Interchangeable Wedge Smoothing Tool with Elastic Retention
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Solution Overview
Problem
Existing bead smoothing tools in the automotive industry face challenges with frequent manipulator round trips for material collection, shim wear leading to production interruptions, and the need for precise wedge positioning while allowing quick and easy replacement, without increasing production costs or compromising quality.
Innovation Solution
A smoothing tool with a removably mounted wedge on a support, equipped with an elastic member for vertical pivoting and reversible interlocking, allowing easy shim replacement and maintaining precise positioning, integrated with a suction system for efficient material collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If the manipulator makes frequent round trips to collect excess material, then the material collection is thorough, but the production rate decreases
Solution Approach 1:
The invention combines the smoothing wedge and suction nozzle into a single integrated tool head. The suction system is positioned to collect excess material at the same location where the wedge smooths the bead, eliminating the need for separate collection trips and enabling continuous operation without interrupting the production flow.
Solution Approach 2:
The suction system operates continuously during the smoothing process, collecting excess material as it is generated. This continuous action eliminates idle round trips and maintains uninterrupted production, thereby improving productivity while ensuring thorough material collection.
2Reliability
If the shim is worn and needs replacement, then the tool can be maintained, but production is interrupted
Solution Approach 1:
The tool head is designed as a modular assembly with the wedge, nozzle, and mounting components as separate segments. This segmentation allows the wedge to be quickly removed and replaced without affecting other parts of the tool or requiring complete disassembly, enabling rapid maintenance during production.
Solution Approach 2:
The wedge is designed with dynamic replaceability, allowing operators to quickly swap worn shims during production runs. The modular design and simplified mounting mechanism enable hot-swapping of components without interrupting the overall production process for extended periods.
3Manufacturing precision
If the wedge is rigidly fixed on the tool, then the positioning is precise, but the wedge cannot bend to adapt to pressure variations
Solution Approach 1:
The wedge is designed with a combination of rigid mounting for precise positioning and flexible material properties that allow it to bend under pressure. The elastic member provides a controlled degree of freedom, enabling the wedge to adapt to pressure variations and bead geometry changes while maintaining its registered position on the tool.
Solution Approach 2:
The wedge material or structure is designed to change its physical parameters (flexibility, bendability) in response to applied pressure, while its mounting position remains fixed and precise. This allows the wedge to conform to different bead conditions without compromising its registered location on the smoothing tool.
4Reliability
If the wedge replacement procedure is complex, then the positioning reliability is maintained, but the replacement time increases
Solution Approach 1:
The wedge mounting system is segmented into discrete, easily manipulated components with simple interlocking features. This segmentation allows the wedge to be quickly removed and replaced using basic hand tools or even hand-tightened connections, significantly reducing replacement time while maintaining positioning reliability through precise locating features.
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
Enables quick and easy replacement of worn shims without interrupting production, maintains precise wedge positioning, and optimizes bead quality and formatting, while reducing production costs and maintaining performance.
Implementation Method 1
retained in a vertical direction via an elastic member which is interposed in joint engagement between the support and the body
Implementation Method 2
a nozzle connected to a suction system to collect the excess material removed by the tool
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a tool (3) for smoothing a bead (2) of adhesive paste material, configured for movement by an automated manipulator (4). The tool (3) comprises a smoothing block (6) for the bead (2) mounted on a support (5). Along a longitudinal direction (L1) of extension of the smoothing tool (3), the tool (3) successively comprises the support (5) and a body (9) carrying the block (6). The block (6) is removably mounted on the body (9) and is immobilized on the body (9) in Euclidean space. The body (9) is removably mounted on the support (5), positioned along longitudinal (L1) and transverse (T1) directions. The body (9) is retained along a vertical direction (V1) by means of an elastic element (10), which is interposed in a joint engagement between the support (5) and the body (9).