Fastener-Free Tight Space Pilot Assembly for Die Alignment
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Solution Overview
Problem
Current metal forming dies are labor-intensive, expensive, and time-consuming to design, manufacture, and modify due to the need for custom-designed and individually crafted components, particularly in tight spaces where additional components are limited.
Innovation Solution
A pilot assembly with a pilot body and ejector pin body featuring a tapered design, retaining ring groove, and spring member that allows for precise alignment and easy installation, reducing the need for extensive machining and enabling efficient operation in tight spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional custom-designed pilot assemblies are used in tight spaces, then alignment precision is achieved, but device complexity and manufacturing time increase significantly
Solution Approach 1:
The patent combines the pilot body, ejector pin, and spring member into a single integrated assembly that functions as one unit. The pilot body includes an integrated ejector pin with a spring member pre-loaded within it, eliminating the need for separate installation of multiple components and reducing overall assembly complexity while maintaining precise alignment capabilities.
Solution Approach 2:
The pilot assembly serves multiple functions simultaneously: the pilot body provides alignment guidance, the integrated ejector pin removes formed parts from the die, and the spring member provides the ejection force. This multi-functional design reduces the number of separate components needed in tight space applications.
2Manufacturing precision
If traditional custom-designed pilot assemblies are used, then alignment precision is achieved, but labor intensity and cost increase
Solution Approach 1:
By integrating the ejector pin and spring member into the pilot body as a single assembly, the patent reduces the number of machining operations, fitting steps, and installation procedures required. This streamlined design reduces labor intensity and manufacturing cost while preserving the precise alignment functionality.
3Manufacturing precision
If traditional pilot assemblies are used in tight spaces, then alignment is achieved, but available space for additional components is insufficient
Solution Approach 1:
The integration of multiple components into a single compact pilot assembly significantly reduces the volume occupied in the die set. The ejector pin is housed within the pilot body, and the spring member is pre-loaded within the ejector pin structure, creating a space-efficient design suitable for tight space applications.
Solution Approach 2:
The patent employs a nested structure where the spring member is contained within the ejector pin, which in turn is integrated into the pilot body. This nesting arrangement minimizes the overall volume required while maintaining all necessary functions.
4Manufacturing precision
If custom mounting and fitting procedures are used, then precision alignment is achieved, but lead time increases
Solution Approach 1:
The integrated design allows the entire pilot assembly to be manufactured as a single unit or pre-assembled module, eliminating multiple sequential steps of custom mounting and fitting. This reduces lead time significantly while maintaining precision alignment through the integrated geometry of the pilot body.
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
The pilot assembly facilitates faster and more cost-effective assembly and modification of metal forming dies by allowing for precise alignment and easy installation, reducing labor and lead time, while maintaining precision and efficiency in forming complex metal parts.
Implementation Method 1
a spring member surrounding at least a portion of the first end portion of the ejector pin body. The spring member has a first end portion oriented away from the stock piece and a second end portion oriented toward the stock piece. The second end portion of the spring member will contact the first shoulder of the ejector pin body.
Data Source
AI summary
A tight space pilot, tight space pilot assembly, and related method includes a tight space pilot that can be installed into a die without fasteners, fastener apertures, or added blocks for mounting. The tight space pilot assembly includes ejectors that are retained by the pilot and a retaining ring that holds the tight space pilot in place in a die member.