Surface Layer Wrapping Assembly Using Elastic Edge Recovery
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Solution Overview
Problem
The existing methods for manufacturing surface-layered parts, such as vehicle armrests, are inefficient as they require manual hooking of the surface layer skin's wrapping portions onto the armrest core, leading to prolonged assembly times and reduced productivity.
Innovation Solution
An apparatus comprising a main support, a pulling device, a base member clamping device, and a relieving device that automates the process of pulling the surface layer member's edge outward, clamping it against the base member, and allowing it to wrap around due to elastic restoring force, thereby integrating the two components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual hooking method is used to attach surface layer skin to base member, then workers can complete the attachment, but assembly time becomes excessively long and productivity decreases
Solution Approach 1:
The patent replaces the manual mechanical hooking operation with an automated pulling device that uses a pulling member to automatically pull the edge of the surface layer member outward and wrap it around the base member. This substitution of manual mechanics with automated mechanical systems directly resolves the contradiction by dramatically reducing assembly time while maintaining attachment quality.
Solution Approach 2:
The patent utilizes the elastic restoring force of the surface layer member itself to accomplish the wrapping action. The pulling device only needs to pull the edge outward, and the material's own elasticity causes it to wrap around the base member automatically. This self-service approach eliminates the need for complex wrapping mechanisms while improving productivity.
2Productivity
If automated pulling device is introduced to wrap surface layer member edge, then productivity improves, but device complexity increases
Solution Approach 1:
The patent divides the manufacturing apparatus into distinct functional modules: a main support for holding the base member, a pulling device with a pulling member for outward pulling, a relieving device for releasing the pulled state, and a clamping device for securing the wrapped edge. This segmentation allows each component to perform its specific function simply, reducing overall device complexity while achieving automation.
Solution Approach 2:
The patent introduces a pulling member as an intermediary tool that mediates between the pulling device and the surface layer member. This simple intermediary component enables automated pulling without requiring complex direct engagement mechanisms, thus improving productivity while minimizing the increase in device complexity.
3Reliability
If surface layer member edge is pulled outward and wrapped around base member, then integration reliability improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent changes the physical state and position of the surface layer member edge through controlled pulling. By pulling the edge outward to a specific position and then releasing it to wrap around the base member, the system achieves reliable integration. The clamping device then secures the wrapped edge in its final position, ensuring both reliability and precision without requiring extremely tight tolerances throughout the process.
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 significantly improves productivity by automating the wrapping process, reducing assembly time, and ensuring reliable integration of the surface layer member with the base member, enhancing product quality and efficiency.
Implementation Method 1
a relieving device that separates the pulling member from the edge of the surface layer member, the edge of the surface layer member having been moved outward with respect to the base member by the pulling device, to allow the edge of the surface layer member to wrap around the edge of the base member owing to an elastic restoring force of the surface layer member
Data Source
AI summary
An apparatus for manufacturing a surface-layered part comprises: a main support that supports a surface layer member to be placed under a base member; a pulling device arranged at a periphery of the main support, wherein the pulling device includes a pulling member that pulls an edge of the surface layer member, which is in a position away from the edge of the base member, outward with respect to the base member; a base member clamping device that fixedly clamps the surface layer member, having been pulled outward by the pulling member of the pulling device, against the main support via the base member placed over the surface layer member; and a relieving device that separates the pulling member from the edge of the surface layer member, which has been moved outward with respect to the base member by the pulling device, to allow the edge of the surface layer member to wrap around the edge of the base member by an elastic restoring force of the surface layer member, thereby integrating them; and a control device that drives and controls the base member clamping device, the pulling device, and the relieving device.