Stepped-Groove Collar and Shaft Locking for Fast Die Assembly
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Solution Overview
Problem
Current metal forming dies are labor-intensive and costly to design, manufacture, and modify due to the need for custom-designed and precision-machined components, requiring substantial lead time and labor for assembly and setup in stamping presses.
Innovation Solution
A collar and shaft assembly featuring a cylindrical shaft with a stepped groove and a collar with a tapered inner sidewall, combined with a retainer ring that securely engages in both the shaft and collar grooves, allowing for easy assembly and providing a strong, tamper-proof connection capable of withstanding large forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom-designed and precision-machined components are used in metal forming dies, then manufacturing precision and reliability are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The shaft and collar are designed as universal, standardized components that can be used across multiple die applications. The shaft features a standardized stepped groove configuration, and the collar has a standardized tapered bore and groove arrangement, allowing them to serve multiple functions in different die stations and progressions without requiring custom design for each application.
Solution Approach 2:
The die set is segmented into modular components including standardized shafts, collars, retainers, punches, and dies. Each component can be independently manufactured, tested, and replaced. The shaft and collar assemblies can be swapped between die stations, and individual punches or dies can be replaced without affecting other components, enabling easy repair and modification.
2Reliability
If custom-designed and precision-machined components are used in metal forming dies, then reliability is improved, but loss of time in manufacturing and setup increases
Solution Approach 1:
Standardized shafts, collars, and retainer rings are pre-manufactured with precise dimensions and features before die assembly. The stepped grooves in shafts and corresponding grooves in collars are pre-formed, and retainer rings are pre-sized to match the groove dimensions. This preliminary preparation of standardized components eliminates the need for time-consuming on-site machining and fitting operations.
Solution Approach 2:
The collar is inserted over the shaft, with the retainer ring nested within the stepped groove of the shaft and the groove of the collar. The retainer ring sits in the recessed portion of the stepped groove, creating a nested arrangement where the collar encompasses the shaft and retainer assembly. This nested structure allows for compact, pre-assembled units that can be quickly installed as complete modules.
3Ease of operation
If a retainer ring is used to connect the collar and shaft, then ease of assembly is improved, but strength of connection may be compromised
Solution Approach 1:
The retainer ring is designed with specific dimensional parameters including a cross-sectional width and thickness optimized for the groove dimensions. The groove depth and width in both the shaft and collar are precisely controlled to match the retainer ring size. The tapered portion of the collar bore changes the geometric parameters to provide a locking action that secures the retainer ring, transforming the simple snap-fit into a mechanically locked connection capable of withstanding high forces.
Solution Approach 2:
The retainer ring serves as an intermediary component that mediates the connection between the collar and shaft. Rather than directly connecting the collar to the shaft, the retainer ring sits in the stepped groove, with the collar's groove engaging the retainer ring and the shaft's stepped groove providing a recessed seating area. This intermediary element distributes loads and provides a mechanical interlock that strengthens the overall connection.
Data Source
AI summary
A collar and shaft assembly utilizing a ring and a multi-stepped groove. The multi-stepped groove permits the ring to be compressed into one groove while the collar is being assembled and then to expand into a different groove that permits the ring to contact surfaces on both the collar and the shaft.