Side-Engaged Plunger Mounting System for Reduced Machining

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Solution Overview

Problem

Existing mounting systems require multiple parts and complex machining operations, leading to increased costs, machining variations, and inefficiencies due to the design's reliance on end-plunger engagement with positioning pins, which results in excessive force requirements and moment forces within the plunger body.

Innovation Solution

A mounting system where the sides of the plunger engage a stud with a cam configuration that allows for desired pull-down and locking actions without increasing the stud size or strength, distributing lateral forces on both sides to eliminate moment forces, using a plunger system with side-mounted cam and stud configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If the end of the plunger is used to engage the positioning pin, then the hold-down engagement is achieved, but the camming angles become too great increasing the force needed and producing moment forces in the plunger body

Engineering Contradiction:

Improvehold-down forceVSAvoidforce requirement

Core Design Contradiction:

ForceVSEase of operation

Solution Approach 1:

Instead of using the end of the plunger to engage the positioning pin, the invention uses the side of the plunger for engagement. This inversion of the engagement location changes the camming geometry, reducing excessive camming angles and the associated force requirements while eliminating moment forces in the plunger body.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The engagement interface is moved from a one-dimensional end engagement to a two-dimensional side engagement. This dimensional change allows for optimized camming angles and force distribution, reducing the force needed to achieve the same hold-down effect.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Force

If the end of the plunger is used to engage the positioning pin, then the hold-down engagement is achieved, but the number of parts and machining operations increases

Engineering Contradiction:

Improvehold-down forceVSAvoidnumber of parts

Core Design Contradiction:

ForceVSDevice complexity

Solution Approach 1:

The invention combines the positioning pin engagement function and the hold-down clamping function into a single plunger component. By using the side of the plunger to engage the positioning pin while simultaneously providing clamping, the design eliminates the need for separate positioning and clamping mechanisms, reducing the total number of parts.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The plunger is designed to perform multiple functions: it provides positioning through side engagement with the positioning pin, delivers hold-down clamping force through its clamping action, and maintains structural integrity by eliminating moment forces. This multi-functionality reduces the number of specialized components needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Force

If the cam is included on the end of the plunger, then the hold-down engagement is achieved, but lateral loads create moment forces affecting system longevity

Engineering Contradiction:

Improvehold-down forceVSAvoidsystem longevity

Core Design Contradiction:

ForceVSReliability

Solution Approach 1:

The cam mechanism is relocated from the end of the plunger to the side of the plunger. This inversion changes the load path so that lateral loads are applied directly to the plunger body rather than creating moment forces. The side-mounted cam engages the positioning pin in a way that eliminates bending moments, improving reliability and longevity.

Inventive Principle:

Principle #13The other way round (Inversion)

4Reliability

If individual locking shanks are used, then the mounting system functions, but each shank must be secured individually increasing time and complexity

Engineering Contradiction:

Improvemounting securityVSAvoidmounting speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

Multiple locking functions are merged into a single plunger component. Instead of requiring individual locking shanks to be secured separately, the single plunger provides both positioning and clamping functions, allowing one component to secure multiple features simultaneously, thereby increasing mounting speed.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The plunger serves as a universal component that performs multiple locking and securing functions. It can engage positioning pins, provide clamping force, and maintain positional accuracy all through a single component that is secured in one location, eliminating the need for multiple individual locking operations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 design reduces machining variations and costs by providing significant clamping forces while minimizing the number of parts and machining operations, enhancing the system's performance and longevity.

Implementation Method 1

the plunger has a plunger cam and the stud has a stud cam

Methodology Applied

Scientific EffectCam mechanism: Cam

Data Source

PatentEP2613902B1Mounting system

Publication Date: 2016.05.25 JERGENS INC

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AI summary

A mounting system (10) including a plunger system wherein the sides of the plunger (14a, 14b) are utilized to engage a stud (16a, 16b, 16c, 16d) and the side of the plunger has a plunger cam that can have virtually any desired cam angle and/or configuration to produce a desired pull down and/or locking action.