Vacuum Panel Hanger for Roller Hemming
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Solution Overview
Problem
Conventional roller hemming systems require complex and time-consuming processes for clamping and loading parts onto a hemming die, involving multiple steps and repeated use of a clamper, leading to high manufacturing costs.
Innovation Solution
A panel hanger apparatus that uses vacuum cups to hold the outer panel, locators to clamp the inner panel, and a locking unit to secure the parts onto a hemming die, eliminating the need for a specific hanger and reducing the need for repeated clamping and un-clamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a specific hanger and clamper are used to clamp and load parts onto the hemming die, then the parts can be securely positioned and clamped, but the process becomes complex and time-consuming with multiple steps including positioning, fixing, and repeated clamping operations
Solution Approach 1:
The patent combines the hanger frame, vacuum cups for outer panel holding, locators for inner panel clamping, and positioning pins into a single integrated panel hanger apparatus. This merging of multiple functions into one apparatus eliminates the need for separate hanger and clamper devices, reducing process complexity while maintaining secure positioning and clamping capabilities
Solution Approach 2:
The panel hanger apparatus is designed as a multi-functional device that simultaneously performs holding (via vacuum cups), clamping (via locators), and positioning (via positioning pins) operations. This universal apparatus replaces multiple specialized tools, simplifying the overall system while achieving reliable part securing
2Reliability
If a specific hanger and clamper are used for clamping and loading parts, then the parts can be securely held and positioned, but the processing time increases due to multiple steps and repeated clamping operations
Solution Approach 1:
The panel hanger apparatus performs all necessary positioning, holding, and clamping actions in a single preliminary operation before the hemming process begins. The vacuum cups, locators, and positioning pins are all activated simultaneously to secure the parts, eliminating the need for subsequent repeated clamping operations during the hemming process
Solution Approach 2:
By merging multiple clamping and positioning functions into one integrated apparatus that operates in a single cycle, the patent eliminates the time-consuming sequence of multiple clamping and un-clamping operations, thereby significantly reducing total processing time while maintaining secure part holding
3Reliability
If repeated clamping and un-clamping operations are performed by the clamper as parts move along the assembly line, then the parts can be secured at different stages, but the system becomes more complex and manufacturing costs increase
Solution Approach 1:
The panel hanger apparatus performs all necessary clamping and positioning actions in advance before the parts enter the hemming process. This preliminary securing eliminates the need for repeated clamping operations at different stages along the assembly line, thereby simplifying the overall system while maintaining reliable part security
Solution Approach 2:
The invention extracts and eliminates the need for the clamper device from the roller hemming system by achieving complete part securing through the integrated hanger apparatus. This removal of unnecessary components simplifies the system structure and reduces manufacturing costs while maintaining the required clamping reliability
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 apparatus simplifies the roller hemming process by securely clamping and positioning parts in a single operation, reducing processing time and manufacturing costs by eliminating the need for a clamper and minimizing repeated clamping cycles.
Implementation Method 1
a plurality of vacuum cups mounted to the hanger frame and adapted to suction/hold the outer panel of the parts by using vacuum pressure
Data Source
AI summary
A panel hanger apparatus for roller hemming is disclosed. The panel hanger apparatus clamps parts and loads the parts onto a hemming die, and comprises a hanger frame, a plurality of vacuum cups mounted to the hanger frame and adapted to hold the outer panel of the parts by using vacuum pressure, and a plurality of locators mounted to an edge of the hanger frame for clamping the inner panel of the parts.