Tangless Coil Insert Feed and Alignment to Prevent Cross-Threading
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Solution Overview
Problem
Existing tools for installing tangless helically coiled inserts require manual loading and suffer from pitching errors and cross-threading issues, necessitating an automated system for efficient installation.
Innovation Solution
An automated installation system comprising a tubular body with a mandrel and a feed tube, a track with a shuttle for controlled delivery, and a vacuum delivery device to automatically feed and install tangless helically coiled inserts, minimizing manual intervention and threading errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual loading of inserts is used, then device complexity is reduced, but productivity decreases and manufacturing precision deteriorates due to pitching errors and cross-threading
Solution Approach 1:
The installation system is divided into distinct functional modules: a feed tube for insert delivery, a tubular body with through-bore for positioning, a mandrel with threaded end segment for gripping, and a reduction nozzle for radial contraction. Each module performs a specific function in the automated insertion sequence, enabling high-speed installation while maintaining manageable system complexity through functional decomposition
Solution Approach 2:
The insert automatically feeds through the feed tube and into the through-bore without manual intervention. The mandrel automatically grips the insert through threading engagement, and the reduction nozzle automatically contracts the insert radially as it passes through, eliminating the need for manual loading operations while maintaining system simplicity
2Manufacturing precision
If automated installation is implemented, then manufacturing precision improves by eliminating pitching errors and cross-threading, but device complexity increases
Solution Approach 1:
The through-bore acts as an intermediary positioning channel that guides the insert from the feed tube to the mandrel, ensuring proper alignment and eliminating pitching errors. The reduction nozzle serves as an intermediary mechanism that gradually contracts the insert radially, preventing cross-threading by controlling the insertion force and angle
Solution Approach 2:
The feed tube pre-position s the insert in the correct orientation and location before it engages with the mandrel. The through-bore pre-aligns the insert with the tapped hole axis, and the reduction nozzle pre-contracts the insert radially, ensuring precise installation without cross-threading or pitching errors
3Productivity
If continuous automated operation is used, then productivity increases, but the risk of seizing increases without proper design
Solution Approach 1:
The mandrel is designed to reciprocate (move back and forth) during the insertion process, creating dynamic motion that prevents the insert and mandrel from seizing together. The reduction nozzle also provides dynamic radial contraction, gradually tightening the insert as it passes through, which maintains continuous operation capability while preventing seizure through controlled movement variations
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
Enables seamless, automated installation of tangless helically coiled inserts with reduced pitching errors and cross-threading, facilitating continuous operation without seizing.
Implementation Method 1
an automated installation system comprising a tubular body with a mandrel and a feed tube, a track with a shuttle for controlled delivery, and a vacuum delivery device to automatically feed and install tangless helically coiled inserts
Data Source
AI summary
An automated installation system, constructed to install tangless helically coiled inserts, includes an installation tool, a track, and an insert separator device. The tool includes a nozzle body defining a through-bore extending along an insertion axis, and a mandrel adapted to reciprocate and rotate within the bore. The track defines a channel extending along a first centerline for the travel of inserts disposed in the channel and to the installation tool. The device is mounted to the track and includes a shuttle adapted to intersect and move in the channel. The shuttle defines a through-bore having an axis aligned to the first centerline when in a first position for acceptance of an insert from the channel, and is aligned to a second centerline for expulsion of the insert from the track and into the installation tool. The second centerline is offset from the first centerline, and intersects the insertion axis.