Modular Pilot Assembly With Integral Stripper for Faster Die Setup
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Solution Overview
Problem
Existing metal forming dies are expensive and time-consuming to construct and install due to the need for custom-designed and handcrafted components, as well as the requirement for precision holes and recesses, which increases lead time and labor costs.
Innovation Solution
A modular pilot assembly with a self-contained stripper is designed for metal forming dies, featuring a pilot with a tapered surface, ejector pins, and a spring retainer, which allows for operable support on a die member without the need for fasteners on the working side, reducing complexity and installation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional custom-designed and handcrafted components are used in metal forming dies, then the die set can be precisely fitted and mounted, but the construction and installation become expensive and time-consuming
Solution Approach 1:
The die set is divided into modular components including pilot assemblies, strippers, and forming stations that can be independently manufactured and then assembled. The pilot assembly itself is segmented into a pilot portion, stripper portion, and spring member that can be separately produced and fitted together, reducing overall manufacturing time while maintaining precision through standardized interfaces
Solution Approach 2:
The pilot assembly is designed to perform multiple functions: it serves as a locating pilot, a stripper for removing formed parts, and a guide for material feeding. This multi-functional design eliminates the need for separate custom-made components for each function, reducing both time and cost while maintaining precise operation
2Strength
If traditional pilot assemblies with fasteners on the working side are used, then secure mounting is achieved, but the footprint in the die member increases and complexity rises
Solution Approach 1:
The fastener is extracted from the working side of the die member and repositioned to the non-working side. The pilot assembly is designed with a fastener aperture in its inner end portion that receives the fastener from the rear, eliminating the need for fasteners on the working side and reducing die assembly complexity while maintaining secure mounting through the same fastener mechanism
3Reliability
If custom-designed components with individual mounting are used, then precise operation is achieved, but labor intensity and cost increase substantially
Solution Approach 1:
The pilot and stripper functions are merged into a single integrated pilot assembly that can be manufactured as one piece or pre-assembled unit. This eliminates the need for separate custom mounting operations for individual pilot and stripper components, reducing labor intensity while maintaining the precise operational reliability needed for metal forming operations
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 the construction and installation of metal forming dies by eliminating the need for custom fasteners and reducing the complexity of die assembly, thereby decreasing costs and lead times while improving efficiency.
Implementation Method 1
A spring member is received over the inner end portion of the pilot
Implementation Method 2
The outer end portion includes a tapered surface
Data Source
AI summary
A pilot assembly has an integral stripper and is coupled to a die member from the non-working side of the die member. The pilot tip precisely locates the stock strip in the metal forming die. The reciprocating ejector pins surrounding the pilot strip the stock from the pilot. The pilot assembly fits into an opening in the die member and can be secured by a single fastener that is received in the bottom of the pilot body of the pilot assembly.