Single-Stroke Assembly Tool for Workpiece Alignment and Press-Fit
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Solution Overview
Problem
Current assembly processes for attaching a first workpiece to a second workpiece and then to a support structure require multiple workstations and steps, which can lead to inefficiencies and potential damage due to misalignment.
Innovation Solution
A tool with a housing and a plunger is used to grip the first workpiece, align it with the second workpiece, and then press both into a subassembly, which is subsequently aligned and pressed onto the support structure in a single down-stroke motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple workstations and tools are used to assemble the first workpiece to the second workpiece and then to the support structure, then the assembly process can be completed, but the number of workstations, components, and steps increases
Solution Approach 1:
The patent combines multiple assembly operations (positioning, aligning, and pressing the first workpiece onto the second workpiece, then pressing the subassembly onto the support structure) into a single tool that performs all operations in one workstation during a single downward stroke, eliminating the need for multiple workstations and reducing process complexity
Solution Approach 2:
The single tool is designed with multiple functions: it positions the first workpiece, aligns it with the second workpiece and support structure, and applies pressing forces for both assembly operations. The tool includes a first pressing surface for the first workpiece, a second pressing surface for the second workpiece, and a third pressing surface for the support structure, allowing it to perform multiple tasks that previously required separate tools and workstations
2Productivity
If the subassembly is pressed onto the pinion shaft without proper alignment, then the assembly operation can be completed quickly, but the subassembly and/or pinion shaft may be damaged
Solution Approach 1:
The tool performs preliminary alignment actions before the pressing operation. The positioning surfaces and alignment features of the tool ensure that the first workpiece is correctly positioned relative to the second workpiece and support structure before forces are applied, preventing misalignment damage while maintaining assembly speed
Solution Approach 2:
The tool acts as an intermediary device between the workpieces and support structure, providing controlled alignment and force application. The tool's positioning surfaces and pressing surfaces mediate the interaction between components, ensuring proper alignment is maintained during the pressing operation to prevent damage
3Measurement precision
If a sensor is added to detect alignment of the subassembly with the pinion shaft, then alignment accuracy can be monitored, but costs increase and the sensor may be obscured
Solution Approach 1:
The tool provides self-alignment through its built-in positioning surfaces and geometric features, eliminating the need for external sensors. The tool's design inherently ensures proper alignment through mechanical constraints and positioning surfaces, making the system self-sufficient for alignment without requiring additional detection systems
Solution Approach 2:
The patent removes the sensor from the system by providing inherent mechanical alignment through the tool's design. The alignment function is extracted from the sensor-based detection system and built into the tool's structure through positioning surfaces and geometric constraints, eliminating the need for separate measurement systems
Data Source
AI summary
A tool for attaching a first workpiece and a second workpiece to one another and to a support structure includes a housing and a plunger. The housing includes a main body, a neck portion, and a shoulder portion. The shoulder portion is disposed between the main body and the neck portion and has an outer diameter that is greater than an outer diameter of the main body. A bore extends from a first end within the main body to a distal end of the neck portion. The plunger is disposed within the bore and extends from the distal end of the neck portion. The plunger is biased in a first direction away from the shoulder portion and includes a gripper operable to extend away from an outer surface of the plunger in an expanded state to engage an inner surface of the first workpiece.