Modular Guided Keeper Base With Integrated Pin Retention
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Solution Overview
Problem
Current metal forming dies are labor-intensive and costly to design, manufacture, and repair due to the need for custom, individually crafted components and precise machining, which increases lead time and expense.
Innovation Solution
A modular guided keeper assembly with a cylindrical base, bushings, guide pins, and a retainer ring system that allows for multiple mounting options and integrated solid stops for guide pin retention, simplifying die construction and reducing costs by enabling easier assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom-designed and handcrafted components are used in metal forming dies, then precision and performance are maintained, but manufacturing cost and labor intensity increase significantly
Solution Approach 1:
The die set is divided into modular components including a base, mounting flange, guide pins, and keepers that can be independently manufactured and assembled. This segmentation allows standardization of parts while maintaining precision through controlled manufacturing processes for each module.
Solution Approach 2:
The base component is designed with multiple functions: it provides mounting surfaces for punches and dies, incorporates guide pin retention features, includes keeper mounting capabilities, and provides alignment references. This multi-functionality reduces the number of separate components needed, lowering manufacturing cost while maintaining precision.
2Reliability
If custom-designed and handcrafted components are used in metal forming dies, then performance is maintained, but lead time increases due to labor-intensive processes
Solution Approach 1:
The modular components are pre-manufactured with precision features built-in during mass production. The base includes pre-formed guide pin retention features, pre-drilled mounting holes, and pre-configured keeper mounting surfaces. This preliminary action eliminates time-consuming on-site machining and fitting operations.
Solution Approach 2:
By segmenting the die set into standardized modules, each component can be manufactured independently through automated processes rather than handcrafting entire assemblies. This enables parallel manufacturing of multiple components, significantly reducing overall lead time while maintaining performance through controlled manufacturing processes.
3Manufacturing precision
If precision machining and custom fitting are performed for die set components, then assembly precision is achieved, but labor intensity and manufacturing cost increase
Solution Approach 1:
The base is designed as a universal mounting platform that integrates multiple functions: punch/die mounting surfaces, guide pin retention, keeper mounting, and alignment features. This consolidation reduces the number of separate precision-machined components needed, simplifying the overall device while maintaining assembly precision through built-in registration features.
Solution Approach 2:
Multiple functions that previously required separate precision-machined components are merged into the single base component. The guide pin retention features, mounting surfaces, and alignment references are integrated into one piece, reducing assembly complexity and eliminating the need for multiple precision fitting operations.
4Adaptability or versatility
If individually designed and constructed components are used in die sets, then specific part requirements are met, but repair and modification costs increase
Solution Approach 1:
The die set is segmented into modular components (base, mounting flange, guide pins, keepers) that can be independently replaced. If one component wears or fails, only that specific module needs to be repaired or replaced rather than the entire die set, significantly reducing repair costs while maintaining the ability to customize specific parts for different applications.
Solution Approach 2:
The base component serves as a universal platform that can accommodate different punches, dies, and configurations through its standardized mounting surfaces and features. This universality allows the same base to be reused across multiple die sets or configurations, reducing the need for custom fabrication during repairs and modifications.
Data Source
AI summary
A modular guided keeper base, guided keeper assembly, and related method includes a modular guided keeper base that mounts to a die member. The guided keeper base has an integrated stop for guide pin retention. The guided keeper base can also accommodate a variety of bushings within the base. The guided keeper base is attached to a die member using a mounting flange(s). Mounting fasteners pass through the fastener holes in the mounting flanges and are anchored in the die member to securely retain the guided keeper assembly in place. A retainer ring is mounted in an associated groove in the base over the heads of the mounting fasteners to prevent unintentional unfastening of the fasteners from the die member.