Joint Bushing Assembly Using Force-Controlled Floating Tools
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Solution Overview
Problem
Current methods for producing joints between components are complex and inefficient, often leading to deformation or damage of easily deformable joint bushings during the assembly process.
Innovation Solution
The method involves introducing the joint bushing into a production tool, such as a press, where the hinge pin is secured by plastic deformation or caulking to prevent falling out, and using floating or spring-mounted tools to avoid damage, allowing for force-controlled movements instead of path-controlled ones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If joint bushings are secured by folding over bushing edges using path-controlled tool movement, then the joint connection is secured, but the easily deformable joint bushings suffer deformation or damage
Solution Approach 1:
The patent transitions from path-controlled tool movement to force-controlled tool movement with floating and spring-mounted tools. This dynamic approach allows the tools to adapt to the actual position and deformation state of the joint bushing during the folding process, preventing excessive force application that would cause damage while still achieving secure connection.
Solution Approach 2:
The patent changes the control parameter from displacement-controlled (path-controlled) to force-controlled. By using spring-mounted tools with adjustable preloads, the system can control the folding process through force parameters rather than strict displacement paths, allowing the easily deformable bushing material to be shaped without damage.
2Ease of manufacture
If multiple production steps are performed in separate workplaces, then each step can be optimized, but the production process becomes complex and inefficient
Solution Approach 1:
The patent combines multiple production steps (introduction of joint bushing, folding of bushing edge, calibration, and securing of hinge pin) into a single integrated press operation. All these steps that were previously performed at separate workplaces are now executed in one tool during one press cycle, simplifying the manufacturing process and improving efficiency.
Solution Approach 2:
The patent designs a universal production tool that performs multiple functions: introducing the joint bushing, folding the bushing edge to secure it, calibrating the bushing position, and securing the hinge pin. This multi-functional tool replaces multiple specialized tools and workplaces, making the production process both simpler and more efficient.
3Ease of operation
If joint bushings are introduced and secured in traditional assembly tools, then the joint components can be assembled, but the easily deformable bushings are damaged or deformed during the process
Solution Approach 1:
The patent employs floating tools and spring-mounted components that can dynamically adapt to the position and deformation of the joint bushing during assembly. This dynamic capability allows the easily deformable bushing to be manipulated without rigid constraints that would cause damage, while still achieving precise final positioning.
Solution Approach 2:
The patent uses spring-mounted tools that provide cushioning force before actual contact with the joint bushing. This beforehand cushioning prevents sudden impact forces that would damage the easily deformable bushing material, allowing gentle introduction and positioning while maintaining dimensional accuracy.
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
This approach simplifies and enhances the efficiency of joint production by securely fastening the hinge pin without impairing its rotary movement and minimizes deformation or damage to the joint bushings, ensuring reliable and durable connections.
Implementation Method 1
using floating or spring-mounted tools to avoid damage, allowing for force-controlled movements instead of path-controlled ones
Implementation Method 2
The insertion of the respective hinge pin and, if necessary, the connection of the hinge pin to the other component forming the articulated connection then also take place in the press or in the tool there. After being inserted into the joint bushing, the respective joint bolt is preferably secured against falling out on this or on the one component in such a way that the rotary movement of the joint bolt in the joint bushing is not impaired as a result. This securing is then carried out, for example, by plastic deformation or caulking of at least one area of the respective hinge pin
Data Source
Figure 1~3
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Figure 5
AI summary
The invention relates to a method for producing a joint between two workpieces or components (1,2), wherein a joint bushing (5) is first inserted into an opening (4) of one component (1) and a joint bolt (6) is then inserted into this joint bushing, to the bolt end (6.3) of which protrudes from the joint bushing (5) the further component (2) can be attached.