Retractable Prewinder Assembly with Infinite Depth Adjustment
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Solution Overview
Problem
Existing methods for installing helically coiled inserts, particularly fine thread sizes, require pre-winders with spacers or shims to accommodate length differences, leading to increased costs, time delays, and tool jamming due to the need for multiple spacer sizes and repetitive assembly/disassembly processes.
Innovation Solution
A prewinder apparatus with a rotatable adapter and infinitely adjustable threaded insert allows for precise control of insertion depth and stop positions, featuring a mandrel that extends axially and a clutch mechanism to prevent over-rotation, enabling efficient and repeatable installation of helically coiled inserts without the need for spacers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spacers or shims are used to accommodate differences in insert length or installation depth, then the installation depth can be adjusted, but additional part costs, time delay, and tool disassembly/reassembly are required
Solution Approach 1:
The patent implements a dynamic adjustment mechanism where the adapter can be rotated to different angular positions, each corresponding to a specific installation depth. This eliminates the need for static spacers or shims that require tool disassembly and reassembly. The adjustable threaded insert within the adapter allows continuous depth control without removing components from the tool.
Solution Approach 2:
The adapter serves multiple functions: it provides depth control through angular positioning, acts as a stop member, and accommodates different insert lengths through the adjustable threaded insert. This multi-functional design replaces the need for multiple separate spacer components, reducing part inventory and assembly time.
2Manufacturing precision
If multiple sizes of spacers or shims are stocked to accommodate different insert lengths, then various installation depths can be achieved, but part costs and inventory requirements increase
Solution Approach 1:
A single adapter component with rotatable positioning and an adjustable threaded insert replaces the need for multiple spacer sizes. The adapter can be configured for different depths by rotation, and the threaded insert can be adjusted axially within the elongated cavity to provide continuous depth control, eliminating the need to stock multiple spacer variants.
Solution Approach 2:
The invention changes the control parameter from discrete spacer thicknesses to continuous angular and axial adjustments. The adapter's rotatable flat surface portion provides angular positioning, while the threaded insert's axial position within the elongated cavity provides continuous depth control, replacing discrete spacer sizes with continuous parameter adjustment.
3Manufacturing precision
If the prewinder is disassembled and reassembled repeatedly to change spacers or shims, then the correct insert depth can be achieved, but costs and time delays increase
Solution Approach 1:
The adapter and threaded insert provide on-the-fly adjustment capabilities without requiring tool disassembly. The operator can rotate the adapter and adjust the threaded insert axial position while the tool remains assembled, enabling rapid depth changes between inserts without breaking the workflow and maintaining high installation speed.
Solution Approach 2:
The adjustable threaded insert within the adapter allows the operator to self-adjust the depth setting for different insert lengths without requiring tool disassembly or specialized service. The mechanism is designed for easy operator adjustment through simple rotation and axial positioning actions.
4Manufacturing precision
If a fixed stop position is provided for the motor, then the coil installation depth is consistent, but tool jamming occurs when the coil reaches the intended installation depth
Solution Approach 1:
The stop position is made dynamic through the rotatable adapter and adjustable threaded insert. The flat surface portion of the adapter can be rotated to different angular positions, and the threaded insert can be adjusted axially within the elongated cavity, allowing the stop position to be precisely tailored to each specific insert and application, preventing premature engagement that causes jamming while maintaining consistent depth control.
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
The solution provides a cost-effective and time-efficient method for installing helically coiled inserts by eliminating the need for spacers and shims, ensuring accurate depth control and preventing tool jamming through the use of a rotatable adapter and adjustable threaded insert.
Implementation Method 1
a prewinder portion slidably displaceable into and out of the body coaxial to a longitudinal axis of the body and the adapter, and biased by a first biasing member toward an extended position
Implementation Method 2
a threaded insert having a plurality of insert threads adapted to engage the plurality of insert engagement threads and a threaded insert body extending into the elongated cavity of the adapter to allow axial displacement while preventing rotation of the threaded insert
Implementation Method 3
an adapter rotatable with respect to the body and releasably connected to the body at operator selected ones of a plurality of rotated positions
Data Source
Figure 1
Figure 2~3
Figure 4~7
AI summary
A prewinder apparatus (12) attachable to a drive tool to install a helical coil insert (18) includes a body connected to the drive tool (20). An adapter rotates and is releasably connected to the body at operator selected positions. A prewinder portion (14) displaces in/out of the body. The prewinder portion translates into the body until a fastener engaged with the prewinder portion contacts a stop member (74) defining a predetermined helical coil insert insertion depth. A mandrel (16) axially extends from the prewinder portion when the prewinder portion moves into the body to rotatably insert the helical coil insert. A clutch engages/disengages the mandrel from a drive member. A second clutch or a stall device stalls the drive tool after coil insertion.