Unitary Swing Lever Assembly for Fast Alignment and Replacement
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Solution Overview
Problem
The existing swing lever assemblies in bodymakers have a large number of components, leading to alignment and maintenance challenges, and require extended downtime for replacement, which affects production efficiency.
Innovation Solution
A unitary swing lever assembly with a reduced number of components is introduced, featuring a single body design that simplifies installation and alignment, eliminating the need for shims and reducing the complexity of the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional multi-component swing lever assembly is used, then the alignment and operation can be precise, but the number of components and assembly complexity increases significantly
Solution Approach 1:
The patent combines multiple separate components (swing lever body, mounting plate, adjustment mechanisms) into a single integrated unitary swing lever assembly. This merging eliminates the need for complex assembly and alignment of multiple parts while maintaining the precise alignment functionality through the unified structure's inherent stability and pre-configured geometry.
2Adaptability or versatility
If a traditional multi-component swing lever assembly is used, then the alignment can be adjusted, but the maintenance time and production downtime increase
Solution Approach 1:
The unitary swing lever assembly is designed as a self-contained module that can be quickly removed and replaced as a single unit. This segmentation at the module level (rather than requiring component-level disassembly) enables rapid maintenance and minimizes production downtime while the assembly itself retains adjustable alignment capabilities through integrated adjustment mechanisms.
Solution Approach 2:
The swing lever assembly is pre-configured with built-in adjustment mechanisms and pre-aligned geometry during manufacturing. This preliminary action allows for quick field adjustments without requiring complex on-site alignment procedures, reducing maintenance time while maintaining adaptability.
3Adaptability or versatility
If multiple components are used in the swing lever assembly, then the functionality can be comprehensive, but the installation steps and complexity increase
Solution Approach 1:
Multiple functional components are merged into a single unitary assembly that provides comprehensive functionality (support, alignment, adjustment, and operation control) through integrated design. This eliminates the need for multiple separate installation steps while maintaining all necessary functional capabilities.
4Productivity
If a unitary swing lever assembly is used, then the installation and maintenance time is reduced, but the initial manufacturing complexity may increase
Solution Approach 1:
The complex functionality is segmented into a single modular unit that can be manufactured as one piece or pre-assembled module. This allows the manufacturing complexity to be concentrated in controlled factory conditions rather than field assembly, improving overall production efficiency by enabling quick installation and replacement.
Data Source
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AI summary
A swing lever assembly (302) includes a unitary body (308). By providing a unitary body (308) for the swing lever assembly (302) the number of elements is substantially reduced which solves the problems stated above. In an exemplary embodiment, the swing lever assembly (302) includes a limited number of components. Further, the swing lever assembly (302) includes a limited number of installation components.