Molded Carrier With Machined Metal Inserts For Precision Positioning
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Solution Overview
Problem
Existing plastic supports for motor vehicle sub-assemblies in assembly lines have imprecise positioning means, leading to positioning accuracy issues of +/- 3 mm, which can cause difficulties during assembly operations.
Innovation Solution
A support made from molded plastic material with integrated metal inserts that are machined to create precise positioning means, including centering and orientation features, allowing for accurate alignment with complementary positioning means on a plate, thereby enhancing positioning precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If positioning means are obtained by molding plastic material, then manufacturing cost is reduced and production is economical, but positioning precision deteriorates to +/- 3 mm
Solution Approach 1:
The support combines plastic material with metal inserts to achieve both economical manufacturing and high positioning precision. The plastic body is molded cost-effectively while metal inserts provide precise positioning features after machining, resolving the contradiction between low-cost molding and high precision requirements.
Solution Approach 2:
The positioning function is segmented from the plastic molding process and assigned to separate metal inserts. This allows the plastic support to be manufactured economically by molding while the metal inserts are precisely machined to provide accurate positioning, eliminating the need for high-precision molding throughout the entire support structure.
2Weight of moving object
If the support structure is made lightweight by molding plastic material, then handling ergonomics is improved, but positioning accuracy deteriorates
Solution Approach 1:
The support uses a composite construction with a lightweight plastic molded body and precision metal inserts. The plastic material provides weight reduction for ergonomic handling, while the metal inserts embedded in the plastic deliver the necessary positioning accuracy of +/- 0.1 mm, resolving the contradiction between lightweight design and positioning precision.
Data Source
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AI summary
The invention relates to a support produced by molding a plastic material, which receives a subassembly (70) for moving same on a serial assembly line, comprising first means for positioning said carrier with respect to the assembly line, and second means for positioning the subassembly relative to said support, characterized in that it comprises metal inserts (24, 26, 28, 32, 34) built into the carrier (21) during the molding thereof, wherein said inserts are then machined so as to at least partially produce the positioning means.