Retaining Ring Forming and Transfer Under Constrained Alignment
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Solution Overview
Problem
Conventional methods for assembling retaining rings are labor-intensive due to variations in dimensions, detangling, aligning, and loading, and require precise escapement and gripper alignment, with the rings often losing flatness, roundness, and orientation during material handling.
Innovation Solution
A system and method for on-demand forming and installing retaining rings by feeding a wire into a forming die, transferring the formed ring to a transfer puck, and installing it into a product assembly while maintaining the ring in a constrained state, using a forming die and tubular die with a roller mandrel to shape and align the ring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If retaining rings are manufactured separately and stored prior to installation, then production flexibility is improved, but dimension variation and loss of flatness/roundness/orientation occur during storage and handling
Solution Approach 1:
The retaining ring is formed in advance within the forming die, maintaining its constrained state throughout the forming process. The formed ring is then transferred directly to the product assembly without intermediate storage or handling, eliminating the time gap between forming and installation that causes dimensional variation.
Solution Approach 2:
The patent combines the retaining ring forming operation with the product assembly operation into a single integrated process. The forming die, transfer mechanism, and product assembly are positioned and coordinated so that forming and installation occur in sequence without interruption, eliminating separate storage and handling steps.
2Manufacturing precision
If retaining rings are detangled and aligned manually prior to installation, then installation accuracy is improved, but labor intensity increases
Solution Approach 1:
The forming die itself performs the alignment function by maintaining the retaining ring in a constrained state during forming. The ring emerges from the die already aligned and positioned correctly, eliminating the need for separate detangling and alignment operations.
Solution Approach 2:
Alignment is performed during the forming process itself rather than as a separate subsequent step. The forming die constrains the wire into the precise ring shape and orientation needed, so alignment is built into the forming operation.
3Productivity
If automated singulation and alignment of retaining rings is implemented, then productivity is improved, but device complexity and precise escapement/gripper alignment requirements increase
Solution Approach 1:
The patent merges the forming and installation operations into a single integrated process using one forming die and one transfer mechanism. This eliminates the need for separate singulation, alignment, and installation mechanisms that would increase system complexity.
Solution Approach 2:
The patent extracts the retaining ring directly from the forming die and transfers it immediately to the product assembly. This direct transfer eliminates the need for intermediate handling, grippers, and escapement mechanisms that would add complexity to an automated system.
4Ease of operation
If retaining rings are handled in an unconstrained state, then flexibility in material handling is improved, but flatness/roundness/orientation must be re-established
Solution Approach 1:
The retaining ring is formed and positioned with correct flatness, roundness, and orientation during the forming process. It is then transferred while maintaining this constrained state, so geometric accuracy is established beforehand and maintained throughout transfer and installation.
Solution Approach 2:
The patent maintains the retaining ring in a constrained state throughout forming and transfer, preventing changes in its geometric parameters (flatness, roundness, orientation). This constraint is removed only at the moment of installation into the product assembly.
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 approach reduces labor and maintains the ring's shape and orientation, enabling efficient, precise installation of retaining rings directly into assemblies like damper tubes, improving shipping density and storage efficiency.
Implementation Method 1
forming, using the forming die, the wire into a formed ring having a ring shape
Implementation Method 2
transferring the formed ring from the forming die to a transfer puck
Implementation Method 3
tubular die configured to cooperate with a roller mandrel to form the formed ring into the retaining ring
Data Source
AI summary
A method for forming and installing a retaining ring comprises: feeding a wire in a linear path into a forming die having a circular bore; forming, using the forming die, the wire into a formed ring having a ring shape; transferring the formed ring from the forming die to a transfer puck; and installing the formed ring, as a retaining ring, in a tube of a product assembly. The formed ring is maintained in a constrained state between forming in the forming die and installation in the product assembly. A system for forming and installing a retaining ring into a product assembly includes a forming die configured to form a wire into a formed ring having a ring shape; and a transfer puck to transfer the formed ring from the forming die. The formed ring is maintained in a constrained state from forming through installation.