Non-Round Core Insertion Alignment via Pushing Force
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Solution Overview
Problem
The insertion of a round blank core with a non-round outside contour into a round blank ring with a non-round inside contour is challenging due to alignment issues, which can disrupt the embossing process and block feeding in stamping processes, as existing technologies do not provide effective methods for aligning non-circular cores with non-circular rings.
Innovation Solution
A transporting device with a pushing-in device and alignment means, including a support ring and alignment mandrel, is used to align and insert the round blank core into the round blank ring by applying a pushing-in force, allowing for relative rotation and shifting to achieve correct alignment and insertion, even when contours are non-circular.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If both the hole in the round blank ring and the outside contour of the round blank core are circular, then the insertion is easy, but the invention is limited to circular contours only and cannot handle non-circular contours
Solution Approach 1:
The patent introduces non-circular contour elements (asymmetric features) on both the round blank core and the hole in the round blank ring. These asymmetric contours are designed to mate with each other, providing automatic alignment and orientation during insertion. The asymmetric features prevent rotational misalignment and ensure correct positioning, thereby maintaining ease of operation while enabling handling of non-circular contours.
Solution Approach 2:
The patent employs guide elements or alignment features as intermediaries between the round blank core and the hole. These intermediary features facilitate the matching and alignment of non-circular contours during the insertion process, enabling versatile contour adaptation while maintaining operational simplicity through guided engagement.
2Manufacturing precision
If the hole center and the round blank center are in substantial alignment, then the insertion accuracy is improved, but the device complexity increases due to alignment mechanisms
Solution Approach 1:
The asymmetric contour features themselves serve as built-in alignment mechanisms. The unique shape of the non-circular contours on the core and hole provide natural guidance for centering and orientation, eliminating the need for separate alignment devices. This achieves high alignment precision while avoiding additional complexity from external alignment mechanisms.
Solution Approach 2:
The non-circular contour features enable self-alignment during insertion. The geometric constraints of the asymmetric shapes automatically guide the round blank core into correct positioning within the hole, achieving precise alignment through the design of the contours themselves rather than through active alignment mechanisms.
3Reliability
If there is twisting or relative shifting of the two round blank parts, then the insertion becomes difficult, but adding alignment constraints increases the device complexity
Solution Approach 1:
The non-circular asymmetric contours are designed to prevent twisting and relative shifting through their geometric interlocking. The unique shape features on the core and hole create mechanical constraints that eliminate rotational freedom and lateral displacement, ensuring reliable insertion without requiring additional constraint mechanisms.
Solution Approach 2:
The asymmetric contour design provides self-constraining functionality during insertion. The geometric features automatically prevent twisting and shifting by their very shape, eliminating the need for separate constraint devices and maintaining simplicity while ensuring insertion reliability.
Data Source
AI summary
An apparatus and a method for inserting a non-round circular-blank core into a non-round hole of a circular-blank ring to create a circular blank. A transporting device transports the circular-blank ring to an insertion location. A feed device transports the circular-blank core to the insertion location. The circular-blank core is positioned on the hole of the circular-blank ring and inserted into the hole with the aid of a pushing-in device, which applies a pushing-in force. If the non-round hole is not in alignment with the non-round circular-blank core, the circular-blank core and the circular-blank ring are rotated relative to one another at the insertion location by generation of the pushing-in force. The circular-blank ring is preferably moved, by the pushing-in force, onto an alignment mandrel, which causes the circular-blank ring to rotate in its circumferential direction until the contours of the circular-blank core and of the hole are in alignment.