Locking Washer Die Forming for Accurate Teeth and Cams

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Solution Overview

Problem

Existing methods for manufacturing washers for locking systems face issues such as undesired displacements during processing, high material usage, restricted load-bearing surfaces, and deformation of the outer periphery, leading to defects and processing challenges.

Innovation Solution

A die assembly with a closed shaping space formed by a lower, upper, and central die, along with a support piece, is used to form washers with radially extending teeth and cams from a blank that can be cut from a strip or wire, allowing for accurate and efficient formation of patterns from the inner to the outer periphery, reducing material consumption and simplifying the process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If washers are manufactured by feeding strip blank through multiple stations with forming and punching, then the tooth pattern and cam pattern can be formed on the washer surfaces, but undesired displacements occur between stations causing defect washers

Engineering Contradiction:

Improvepositioning accuracy of washer patternsVSAvoidproduction consistency of washers

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent combines multiple forming and punching operations into a single die assembly where all patterns are formed simultaneously from a blank in one positioning step, eliminating cumulative displacement errors that occur when feeding through multiple stations sequentially

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The die assembly is pre-configured with all necessary forming and punching features positioned relative to the blank's outer periphery, allowing the blank to be positioned once and all operations to be performed accurately without subsequent repositioning

Inventive Principle:

Principle #10Preliminary action

2Shape

If the outer periphery is punched out to form the washer, then the washer shape is created, but the outer periphery receives a sharp edge causing problems in further processing

Engineering Contradiction:

Improvewasher outer periphery shapeVSAvoidprocessing difficulty of washer edges

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The die assembly pre-forms the outer periphery with a rounded contour during the initial blank positioning, eliminating the need for subsequent edge processing and avoiding sharp edges before further manufacturing steps

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the geometric parameter of the outer periphery from a sharp punched edge to a rounded contour by modifying the die geometry, which eliminates processing difficulties associated with sharp edges

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If the outer periphery is deformed during punching out to form an edge zone free from pattern, then the punch can rest during punching, but the load transferring surface of the washer is restricted

Engineering Contradiction:

Improvepunching process feasibilityVSAvoidload bearing surface area of washer

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

The patent changes the geometric parameter of the outer periphery from a deformed contour with pattern-free zone to a rounded contour that extends the load-bearing surface to the actual outer edge, achieved by reforming in the die assembly

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The die assembly pre-forms the complete washer shape including the outer periphery before punching, allowing the punch to operate on a pre-formed contour rather than deforming the edge zone during punching

Inventive Principle:

Principle #10Preliminary action

4Reliability

If washers are formed with patterns covering the upper and lower surfaces, then locking functionality is achieved, but the total amount of blank material required is quite high

Engineering Contradiction:

Improvelocking functionality of washerVSAvoidblank material consumption

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent optimizes the blank geometry parameters to match the final washer shape more closely, reducing excess material that would be required to accommodate pattern formation from a traditional rectangular strip blank

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20220226879A1Method and a Device for the Manufacturing of Washers for Locking and Washer for Locking

Publication Date: 2022.07.21 NORD-LOCK AB

AI summary

A method for the manufacturing of circular washers for locking from blanks, the washer having a central hole, a first side comprising a pattern of radially extending teeth and a second side comprising a pattern of radially extending cams.The method is especially characterized in the steps ofproducing a washer blank having an annular shape;introducing the washer blank into a die assembly for forming a closed shaping space by a lower die portion, an opposing upper die portion, a central die portion and a support piece, the central die portion extending through a washer blank central hole;forming the blank to a washer by mutual movement of said lower and upper die portions;opening the closed shaping space to extract the formed washer.The invention also relates to a device and a washer.