Tapered Pilot Assembly for Easier Die Mounting and Stock Alignment
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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, including pilots, which are expensive and time-consuming to construct and install.
Innovation Solution
A multi-station metal forming die with a pilot assembly featuring a pilot with a cylindrical shoulder, tapered transition portions, and fastener reliefs, allowing for secure mounting within a die member using a single machine setup, reducing machining complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If custom-designed and precision-machined pilot components are used, then locating accuracy and reliability are improved, but manufacturing complexity and cost increase
Solution Approach 1:
The pilot is divided into distinct functional segments: a cylindrical body portion for mounting, a tapered transition portion for guiding, and a locating end portion for positioning. This segmentation allows each portion to be optimized independently while simplifying overall manufacturing compared to custom precision-machined pilots.
Solution Approach 2:
The pilot design incorporates multiple functions in a single component: it serves as a mounting element, a guide for stock transition, and a locating feature. The standardized cylindrical body with mounting holes makes it a universal component that can be used across different die applications, reducing the need for custom-designed pilots.
2Reliability
If custom-designed and precision-machined pilot components are used, then locating accuracy and reliability are improved, but manufacturing time and lead time increase
Solution Approach 1:
The pilot is designed with pre-formed features including the cylindrical body, tapered transition portion, and mounting holes that can be created through simpler, faster processes. This preliminary structuring eliminates the need for time-consuming precision machining operations after the pilot is manufactured.
Solution Approach 2:
The pilot uses simpler, more economical manufacturing processes that allow for faster production and lower cost. The design accepts that the pilot may be a less durable component that can be replaced more easily, trading long-term durability for reduced manufacturing time and cost.
3Ease of operation
If tapered transition portions are used, then ease of stock entry and alignment are improved, but risk of binding increases
Solution Approach 1:
The pilot features a tapered transition portion with a specific taper angle that is optimized for guiding stock entry. This localized taper provides the necessary guidance and alignment, while the rest of the pilot maintains a cylindrical shape to prevent binding. The local quality of the tapered section addresses the entry issue without compromising the overall performance.
Data Source
AI summary
A pilot assembly having a shaped portion and a shaped fastener relief for attachment to a die. The pilot assembly includes a fastener with a shaped washer that engages the shaped fastener relief to permit installation and removal of the pilot from the die. The shaped portion of the pilot assembly helps to locate and center the stock down the pilot assembly toward the die.