Surface-Layer Part Assembly with Pull-Release Edge Wrapping
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Solution Overview
Problem
The existing methods for manufacturing surface-layered parts, such as vehicle armrests, are inefficient due to the manual process of attaching the armrest skin to the core, which requires workers to hook the wrapping portions by hand, resulting in low productivity.
Innovation Solution
An apparatus comprising a main support, a pulling device, a base member clamping device, and a relieving device that automates the process of wrapping the surface layer member around the base member using a controlled mechanism to pull, clamp, and release the surface layer member, allowing it to wrap around the base member via elastic restoring force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual hooking of wrapping portions is used, then workers can attach the armrest skin to the core, but the assembly time becomes excessively long and productivity is low
Solution Approach 1:
The surface layer member is designed with elastic restoring force that automatically wraps it around the base member after the pulling force is removed. The member serves itself by utilizing its own elasticity to complete the wrapping action, eliminating the need for manual hooking and significantly reducing assembly time
Solution Approach 2:
The pulling device performs preliminary action by pulling the surface layer member outward before the wrapping occurs. This preliminary pulling creates the necessary tension and positioning, allowing the subsequent automatic wrapping to happen efficiently when the pulling force is released
2Extent of automation
If the surface layer member is pulled outward to wrap around the base member, then automated wrapping is achieved, but the member may be scratched or damaged during the process
Solution Approach 1:
The pulling device is designed to apply controlled pulling force that creates tension without exceeding the damage threshold of the surface layer member. The system cushions the pulling action to prevent scratches while still achieving the necessary outward movement for wrapping
Solution Approach 2:
The pulling force is carefully controlled within specific parameter ranges that are sufficient to pull the member outward for wrapping but remain below the threshold that would cause scratching or damage. The elastic properties of the member are utilized within safe stress limits
3Stability of the object's composition
If the surface layer member is fixed to the main support during pulling, then stable positioning is achieved, but the member cannot wrap around the base member edge
Solution Approach 1:
The fixing mechanism is segmented into two distinct phases: during the pulling phase, the member is fixed to provide stable positioning; during the wrapping phase, the fixing is released to allow the member to wrap around the base member edge. This segmentation allows both stability and wrapping capability to be achieved at different stages
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
This solution significantly improves productivity by automating the attachment process, reducing the time required for assembly and ensuring consistent quality by preventing the surface layer member from being scratched and ensuring reliable wrapping around the base member.
Implementation Method 1
to allow the edge of the surface layer member to wrap around the edge of the base member owing to an elastic restoring force of the surface layer member
Data Source
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AI summary
An apparatus for manufacturing a surface-layered part comprises: a main support that supports a surface layer member to be placed under a base member; a pulling device arranged at a periphery of the main support, wherein the pulling device includes a pulling member that pulls an edge of the surface layer member, which is in a position away from the edge of the base member, outward with respect to the base member; a base member clamping device that fixedly clamps the surface layer member, having been pulled outward by the pulling member of the pulling device, against the main support via the base member placed over the surface layer member; and a relieving device that separates the pulling member from the edge of the surface layer member, which has been moved outward with respect to the base member by the pulling device, to allow the edge of the surface layer member to wrap around the edge of the base member by an elastic restoring force of the surface layer member, thereby integrating them; and a control device that drives and controls the base member clamping device, the pulling device, and the relieving device.