Integrated Stock Lifter Assembly With External Spring and Hardened Cap
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Solution Overview
Problem
Current metal forming dies are labor-intensive and costly to design, manufacture, and modify due to the custom nature of their components, and existing stock lifter assemblies are prone to shearing and require extensive setup, which complicates the process and increases expenses.
Innovation Solution
A stock lifter assembly with a cylindrical guide pin body, cap, base, spring member, and retainer that allows for secure and efficient longitudinal movement of stock pieces between converging and diverging die members, reducing the number of components and minimizing space within the die assembly, while using a securing member and retainer groove for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional stock lifter assemblies with hardened round pins guided in drilled holes are used, then the stock can be lifted off the tooling surfaces, but the number of components increases and the space required within the die assembly increases
Solution Approach 1:
The patent combines multiple traditional stock lifter components into a single integrated lifter assembly consisting of a base, guide pin, and cap. The guide pin is directly mounted in the base and extends through the cap, eliminating the need for separate retaining pins, oversized heads, and multiple guiding components. This merging reduces component count while maintaining the stock lifting function.
Solution Approach 2:
The guide pin serves multiple functions: it guides the stock lifter assembly, provides structural support, and works with the cap and base to retain the lifting mechanism. The single integrated assembly performs both guiding and retaining functions that traditionally required separate components, reducing overall device complexity.
2Reliability
If traditional stock lifter assemblies with driving force behind the pin are used, then the stock can be lifted, but shearing of the guiding component and/or retaining pin can occur
Solution Approach 1:
By merging the guide pin, base, and cap into an integrated assembly, the patent eliminates weak points where separate retaining pins and guiding components could shear under driving forces. The unified structure distributes stresses more effectively and removes vulnerable joints.
Solution Approach 2:
The guide pin has a rounded end that contacts the cap, creating a curved contact surface that distributes the driving force more evenly. This rounded geometry reduces stress concentration compared to flat or sharp-edged components, decreasing the likelihood of shearing.
3Adaptability or versatility
If custom-designed and handcrafted components are used in metal forming dies, then the die can be designed for a particular part, but the process becomes labor intensive and requires substantial lead time
Solution Approach 1:
The integrated stock lifter assembly can be designed in various configurations to suit different die requirements while maintaining a standardized core structure. This allows customization for specific parts without requiring completely custom components, reducing labor intensity while preserving adaptability.
Solution Approach 2:
The die assembly is divided into modular components (base, guide pin, cap) that can be manufactured separately and assembled. This segmentation allows for standardized manufacturing of individual components while still enabling custom die designs through different combinations and configurations.
4Manufacturing precision
If precision holes and recesses are carefully machined in the die set for mounting individual components, then the components can be securely mounted, but the process becomes quite labor intensive and requires substantial lead time
Solution Approach 1:
By combining multiple mounting features into a single integrated assembly, the patent reduces the number of precision holes and recesses that must be machined in the die set. The base, guide pin, and cap work together as one unit, requiring fewer precise mounting locations and reducing both manufacturing time and setup complexity.
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 solution simplifies the design and operation of metal forming dies by reducing component complexity and enhancing the stability of the stock lifter assembly, thereby lowering production costs and improving the efficiency of metal forming processes.
Implementation Method 1
The stock lifter assembly includes a spring member that has a generally hollow interior with an outer end portion oriented toward the stock piece and an inner end portion oriented away from the stock piece. The outer end portion of the spring member contacts a surface of the outer end portion of the cap. The inner end portion of the spring member contacts the exterior shoulder formed on the base.
Data Source
AI summary
A stock lifter for metal forming dies includes a self-contained assembly. The assembly includes a guide pin that reciprocates within a base. A hardened end cap, which contacts the stock, is attached to the guide pin. A spring is located on the exterior surface of a portion of the base and surrounds the guide pin body. One end of the spring contacts a surface on the cap, while the other end of the spring contacts a surface on the base or an optional mounting flange that is attached above the base. Thus, the stock lifter assembly has a hardened cap for the stock to slide on and a larger, externally mounted spring that provides longer life for the stock lifter. The stock lifter assembly can be made of several different lengths and sizes by using longer or wider guide pins and springs.