Tapered Pilot Assembly for Accurate Die Stock Centering
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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 cylindrical shoulder, tapered transition portions, and fastener reliefs for secure mounting, allowing for easier installation and reduced machining complexity, enabling a one-piece construction from a solid bar for increased accuracy and reduced costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If custom-designed and precision-machined pilot components are used, then locating accuracy is improved, but manufacturing cost and lead time increase
Solution Approach 1:
The pilot assembly is designed as a universal component that can be used across multiple die sets and applications. The standardized dimensions and configurations allow the same pilot assembly to serve different locating requirements, eliminating the need for custom-designed pilots for each application while maintaining accurate locating functionality.
Solution Approach 2:
The pilot assembly is divided into separable components including the pilot body, mounting portion, and fastening elements. This segmentation allows for simplified manufacturing of individual components, easier assembly into die sets, and reduced machining complexity compared to monolithic custom-designed pilots.
2Manufacturing precision
If custom-designed pilot components are used, then locating accuracy is improved, but installation time and complexity increase
Solution Approach 1:
The pilot assembly is pre-assembled with all mounting features, fastening elements, and sealing components integrated before installation into the die set. This preliminary preparation eliminates the need for complex assembly operations during die set construction, significantly reducing installation time while maintaining precise locating accuracy.
Solution Approach 2:
Multiple functional elements are merged into a single integrated pilot assembly including the locating surface, mounting portion, fastening features, and sealing elements. This consolidation reduces the number of separate components that need to be installed and aligned, simplifying the installation process while preserving accurate locating functionality.
3Manufacturing precision
If custom-designed pilot components are used, then locating accuracy is improved, but ease of repair and modification decrease
Solution Approach 1:
The pilot assembly is designed with separable components and standardized mounting features that allow for easy removal, replacement, and modification. Individual elements such as fastening components and sealing elements can be independently serviced or replaced without affecting the entire pilot assembly or requiring complex disassembly procedures.
Solution Approach 2:
The standardized design of the pilot assembly allows for interchangeability with other pilots in the same series, enabling easy replacement and repair. If one pilot assembly is damaged or needs modification, a standardized replacement can be installed without custom machining, maintaining locating accuracy while simplifying repair operations.
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.