Attachment Pad Forming Tool With Counterbalance for Spring-Back
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Solution Overview
Problem
Existing pad forming tools for sheet material in automated assembly lack uniform bias force maintenance, fail to account for sheet material 'spring-back', do not provide support for the area around the formed pad, and struggle with off-plane orientation, leading to unwanted deformation and inaccurate pad formation.
Innovation Solution
A tool with a slide block biased by actuators, adjustable counterbalance devices, and position sensors to maintain uniform force, accommodate spring-back, and support off-plane orientations, featuring workpiece clamps to prevent deformation, and multi-degree-of-freedom movement for precise pad formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the tool is articulated by the robot to reach various target points on sheet material, then the tool can access different locations, but the bias force applied to the slide block varies widely and cannot be maintained uniformly
Solution Approach 1:
A counterbalance device is introduced to counteract the variable bias force applied to the slide block during robot articulation. The counterbalance device generates an opposing force that compensates for changes in gravitational and inertial forces, maintaining a substantially uniform net bias force on the slide block throughout the tool's range of motion, thereby resolving the contradiction between tool accessibility and force uniformity
2Manufacturing precision
If the sheet material is formed between a forming die and fixed anvil, then the pad can be formed at a predefined position, but the tool does not account for spring-back causing inaccurate pad formation
Solution Approach 1:
The system performs preliminary measurement of the sheet material's spring-back characteristics before pad formation. Position sensors measure the actual position of the sheet material and the force applying device, and the controller uses this data to calculate and compensate for spring-back effects, adjusting the forming position in advance to achieve accurate pad formation despite material deformation
3Device complexity
If the tool does not provide support for the area around the pad formation location, then the tool structure remains simple, but unwanted deformation or curving of the sheet material occurs
Solution Approach 1:
The force applying device is segmented into multiple independent piston modules positioned in tandem. Each module includes a housing with a void and a piston that can be independently controlled. This segmentation allows localized support forces to be applied to different areas of the sheet material around the pad formation location, preventing unwanted deformation while maintaining reasonable structural complexity
4Device complexity
If the tool does not accommodate off-plane orientation of incoming sheet material, then the tool design is simpler, but the ability to repeatably and accurately locate the sheet material relative to the slide block is reduced
Solution Approach 1:
The force applying device incorporates controlled movement capabilities that allow it to adapt dynamically to off-plane orientations of the incoming sheet material. The piston modules can adjust their positions and angles to accommodate variations in sheet material alignment, enabling repeatable and accurate location of the sheet material relative to the slide block while managing the increased design complexity through adaptive mechanisms
Data Source
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AI summary
A tool for forming an attachment pad on a sheet material includes an anvil supported on a housing and defining a working axis for forming the pad. A slide block is supported on the housing for movement at least along the working axis, and a die block is supported opposite the slide block and is movable in directions along the working axis to cooperate with anvil to form the pad. At least one actuator on the housing biases the slide block in a direction toward the die block. The actuator is operable in a first mode wherein the slide block is movable toward and away from the die block, and a second mode wherein the slide block is locked against movement in a direction away from the die block. A selectively adjustable counterbalance device cooperates with the actuator to counterbalance a force applied to the slide block by the actuator.