Variable Crimp Tool Roller Adjustment for Flange Thickness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing crimping assemblies for securing cover parts to motor vehicle structural members face challenges in accommodating variations in structural member thickness, leading to inconsistent sealing and potential failure in securing the cover part effectively.
Innovation Solution
A crimping assembly featuring a first roller and a second roller that move relative to each other, with a Schmidt coupling mechanism allowing torque transfer across different axes of rotation, enabling the assembly to adjust to varying structural member thicknesses by moving the second roller towards or away from the first roller, ensuring a tight fit and secure crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed roller configuration is used in the crimping assembly, then the structure is simple and stable, but it cannot accommodate variations in structural member thickness
Solution Approach 1:
The patent applies the dynamics principle by making the second roller movable relative to the first roller along the axis of rotation. This allows the roller configuration to dynamically adjust to varying flange thicknesses during operation, transforming a static system into an adaptive one that maintains effective crimping across different structural member dimensions
2Adaptability or versatility
If a movable second roller is introduced to accommodate thickness variations, then adaptability improves, but the device complexity increases
Solution Approach 1:
The Schmidt coupling acts as an intermediary mechanism between the drive shaft and the second roller. It enables torque transfer while accommodating axial movement of the second roller, effectively mediating between the rotational drive and the linear adjustment needed for thickness variation accommodation without requiring complex control systems
3Reliability
If the second roller is constrained to maintain constant pressure, then sealing consistency improves, but the ability to accommodate thickness variations deteriorates
Solution Approach 1:
The patent applies parameter changes by allowing the axial position of the second roller to vary according to flange thickness. This dynamic parameter adjustment enables the system to maintain optimal contact pressure and sealing consistency across different thickness conditions, transforming a fixed-parameter system into one that adapts its parameters to maintain 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 assembly effectively secures cover parts to structural members with adjustable pressure and flexibility to accommodate thickness variations, ensuring a consistent and reliable seal across different flange configurations without interrupting operation.
Implementation Method 1
A Schmidt coupling mechanism allowing torque transfer across different axes of rotation
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A crimping assembly is provided for securing a cover part to a structural member. The crimping assembly includes a housing, a drive shaft disposed within the housing and rotatable in a first direction, and a first roller fixedly secured to the drive shaft and rotatable therewith. The crimping assembly also includes a slide shaft disposed within the housing and rotatable in a second direction. A second roller is fixedly secured to the slide shaft and rotatable therewith. A drive mechanism is operably coupled to the drive and slide shafts to roll the first and second rollers over the cover part to secure the cover part to the structural member. A coupling mechanism is operably connected between the drive shaft and the slide shaft to allow movement of the slide shaft towards and away from the drive shaft during operation of the crimping assembly to accommodate variations in flange thickness.