Modular Pilot Assembly with Self-Contained Stripper for Metal Forming Dies
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Solution Overview
Problem
Current metal forming dies are labor-intensive and costly to design, manufacture, and modify due to the need for custom, precision components and complex assembly processes, which also result in the stock strip sticking to pilot pins during the forming process.
Innovation Solution
A modular pilot assembly with a self-contained stripper, featuring a cylindrical pilot body with a press-fit insert and ejector pins, which includes a spring mechanism for automatic stripping and a single screw mounting system for easy installation, reducing the number of components and preventing sticking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom, precision components are used in metal forming dies, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The die assembly is divided into modular units: standardized die members with pre-drilled holes, separate pilot pins, and independent stripper components. This segmentation allows each component to be manufactured independently with standard tolerances, reducing overall complexity while maintaining precision through modular assembly
Solution Approach 2:
The die members are designed with universal features including pre-drilled holes and standardized mounting configurations that can accommodate multiple pilot pins and various forming tools. This universality reduces the need for custom-machined components for each specific die configuration, simplifying the overall device while maintaining precision
2Manufacturing precision
If custom, precision components are used in metal forming dies, then manufacturing precision is improved, but labor intensity and manufacturing time increase
Solution Approach 1:
Holes and mounting features are pre-drilled and prepared in the die members before final assembly. Pilot pins and other components are manufactured as standardized parts in advance. This preliminary preparation eliminates time-consuming on-site machining and fitting operations, significantly reducing lead time while maintaining precision through controlled factory manufacturing
Solution Approach 2:
The die is segmented into independently manufacturable components that can be produced simultaneously in different locations and then quickly assembled. This parallel manufacturing approach, enabled by segmentation, reduces total lead time while maintaining precision through standardized interfaces
3Device complexity
If pilot pins are used without self-contained stripper, then device complexity is reduced, but reliability deteriorates due to sticking
Solution Approach 1:
The stripper mechanism is merged with the pilot pin assembly into a single integrated unit. The stripper components are positioned and retained by the pilot body itself, creating a self-contained assembly that ensures reliable stripping action while maintaining relative simplicity. The merger eliminates the need for separate, loosely-fitted stripper components that could fail
4Adaptability or versatility
If multiple separate components are used in pilot assembly, then adaptability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The pilot assembly is segmented into a pilot body, pilot pin, and integrated stripper components that can be manufactured separately using standard processes. This segmentation maintains adaptability by allowing independent optimization of each component while the standardized interfaces simplify the assembly process
Solution Approach 2:
The pilot body is designed as a universal component that can accommodate different pilot pins and stripper configurations for various forming applications. This universality provides adaptability across different die configurations while simplifying manufacture by using a standardized base component rather than custom-machined assemblies
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 modular pilot assembly simplifies installation, reduces manufacturing costs, ensures consistent stripping of the stock strip, and enhances the efficiency and durability of metal forming dies by minimizing sticking issues and requiring fewer components.
Implementation Method 1
a spring member having a generally hollow interior that is received onto and over the spring retainer collar on the inner end portion of the pilot body. The spring member has an outer end oriented toward the stock strip, operably engaging the inner end of the ejector pin to bias the ejector pin outwardly to the extended position
Implementation Method 2
A pilot assembly with self-contained stripper for multi-station progressive metal forming dies having at least two mutually converging and diverging die members between which an elongate stock strip is shifted longitudinally to form parts from the stock strip. The pilot assembly includes a pilot body configured for operable support on an associated die member... a pilot insert having at least a portion thereof shaped for press fit reception in the central aperture of the pilot body
Data Source
AI summary
A pilot assembly and method has a cylindrical pilot body with a pilot insert having tapered outer end. The pilot assembly has at least one inwardly curved sidewall relief, as well as internally mounted reciprocating ejector pins with outer ends that protrude through holes in the outer body end to strip stock from the pilot. A spring has its outer end mounted in the groove in the pilot body, and an inner end attached to the inner end of the pilot insert in a pre-tensed condition. A cap screw has an enlarged head that has at least a portion thereof fit into the pilot sidewall relief, and a threaded shank that anchors the pilot in an associated die member.