CROWDER ASSEMBLIES, HEMMING APPARATUS, AND RELATED COMPONENTS FOR MANUFACTURING OPERATIONS

Description

INTRODUCTION

Hemming (e.g., roller hemming operations) can be used to hem together panels in manufacturing operations. Hemming devices can interfere with other components during hemming operations, and efforts to address such interferences can hinder dimensional accuracy, repeatability, and/or throughput. For example, hemming devices can clog with debris (such as oil and/or metallic dust) such that the clogged devices lock-up, which can cause downtime of the hemming operations while the clogged devices are disassembled and cleaned.

SUMMARY

In one or more embodiments, a crowder assembly for manufacturing operations includes a base, a first support bar coupled to the base and extending relative to an outer face of the base, and a second support bar coupled to the first support bar and oriented at an angle relative to the first support bar. The second support bar includes an opening. The crowder assembly includes a crowder block positioned in the opening of the second support bar, and a flat spring. The flat spring includes a first end segment coupled to the base, and a second end segment coupled to the crowder block. The flat spring biases the crowder block in response to movement of the crowder block.

In one or more embodiments, a hemming apparatus for manufacturing operations includes a table that includes a plurality of table recesses formed in a plurality of table surfaces. The hemming apparatus includes a plurality of crowder assemblies aligning with the plurality of table recesses. At least one crowder assembly of the plurality of crowder assemblies includes a base positioned outwardly of a respective table recess of the plurality of table recesses, a first support bar coupled to the base and extending relative to an outer face of the base, and a second support bar coupled to the first support bar and oriented at an angle relative to the first support bar. The second support bar includes an opening. The at least one crowder assembly of the plurality of crowder assemblies includes a crowder block positioned in the opening of the second support bar, and a flat spring positioned at least partially between the crowder block and the base.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only exemplary embodiments and are therefore not to be considered limiting of its scope, may admit to other equally effective embodiments.

FIG. 1 is a schematic partial axonometric view of a hemming apparatus for manufacturing operations, according to one or more embodiments.

FIG. 2 is a schematic axonometric view of an exemplary crowder assembly, according to one or more embodiments.

FIG. 3 is a schematic side view of the crowder assembly shown in FIG. 2, according to one or more embodiments.

FIG. 4 is a schematic front view of the crowder assembly shown in FIGS. 2 and 3, according to one or more embodiments.

FIG. 5 is a schematic top view of the crowder assembly shown in FIGS. 2-4, according to one or more embodiments.

FIG. 6 is a schematic axonometric view of an exemplary crowder assembly, according to one or more embodiments.

FIG. 7 is a schematic side view of the crowder assembly shown in FIG. 6, according to one or more embodiments.

FIG. 8 is a schematic front view of the crowder assembly shown in FIGS. 6 and 7, according to one or more embodiments.

FIG. 9 is a schematic top view of the crowder assembly shown in FIGS. 6-8, according to one or more embodiments.

To facilitate understanding, identical reference numerals have been used, where possible, to designate identical elements that are common to the figures. It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.

DETAILED DESCRIPTION

The present disclosure relates to crowder assemblies, hemming apparatus, and related components for manufacturing operations. In one or more embodiments, crowder assemblies are used to retain panels that are hemmed together using a hemming apparatus. For example, a crowder assembly described herein can be used to lock an outer panel in place while an inner panel is hemmed (e.g., bent using a roller) to hem the inner panel and the outer panel together. The crowder assembly can include a crowder block that is movable up and down. The roller can pass over the crowder block to move the crowder block down such that the crowder block does not interfere with the roller during hemming. The crowder block can abut against one or more of the panels to retain the one or more panels in place laterally while the panels are hemmed together. After the one roller passes over the crowder block, the crowder block is biased back upward by a flat spring. The panels hemmed together can form a part, such as a vehicle (e.g., automotive) part.

The disclosure contemplates that terms used herein such as “couples,” “coupling,” “couple,” and “coupled” may include but are not limited to welding, fusing, melting together, interference fitting, and/or fastening such as by using bolts, threaded connections, pins, and/or screws. The disclosure contemplates that terms such as “couples,” “coupling,” “couple,” and “coupled” may include but are not limited to integrally forming. The disclosure contemplates that terms such as “couples,” “coupling,” “couple,” and “coupled” may include but are not limited to direct coupling and/or indirect coupling, such as indirect coupling through components such as links, blocks, and/or frames.

FIG. 1 is a schematic partial axonometric view of a hemming apparatus 100 for manufacturing operations, according to one or more embodiments.

The hemming apparatus 100 includes a table 110 that includes a plurality of table recesses 111 formed in a plurality of table surfaces 112. The hemming apparatus 100 includes a plurality of crowder assemblies 200 aligning with the plurality of table recesses 111. The crowder assemblies 200 are positioned outwardly of an outer perimeter of a support face 113 of the table 110. The support face 113 is shaped and sized to support two or more panels during a hemming operation. Crowder blocks 240 of the crowder assemblies 200 are positioned to abut against at least one of the two or more panels to retain the at least one of the two or more panels in position while the two or more panels are hemmed together.

The table 110 and the crowder assemblies 200 are mounted to a platform 103.

FIG. 2 is a schematic axonometric view of an exemplary crowder assembly 200, according to one or more embodiments. The crowder assembly 200 can be used as one or more (such as part or all) of the crowder assemblies of the hemming apparatus 100 shown in FIG. 1.

FIG. 3 is a schematic side view of the crowder assembly 200 shown in FIG. 2, according to one or more embodiments.

FIGS. 1, 2, and 3 are described herein together. The crowder assembly 200 includes a base 210 and a first support bar 220 coupled to the base 210 (such as by using welding) and extending relative to an outer face 211 of the base 201. The crowder assembly 200 includes a second support bar 230 coupled to the first support bar 220 (such as by using welding) and oriented at an angle A1 relative to the first support bar 220. In one or more embodiments, the angle A1 is within a range of 85 degrees to 95 degrees, such as about 90 degrees. In one or more embodiments, the first support bar 220 is oriented vertically (e.g., parallel to the X-Z plane) and the second support bar 230 is oriented horizontally (e.g., parallel to the X-Y plane). In one or more embodiments, the second support bar 230 extends at least partially past a front face 212 of the base 210, as shown in

FIGS. 2 and 3. The base 210 includes a plurality of fastener openings 215 that extend through the base 210. A plurality of fasteners can extend through the fastener openings 215 and into the platform 103 (shown in FIG. 1) to mount the crowder assembly 200 to the platform 103. The second support bar 230 includes a pair of tapered edges 235, 236. The second support bar 230 extends into the respective table recess 111 such that the pair of tapered edges 235, 236 are positioned at least partially in the respective table recess 111.

The second support bar 230 is spaced from the base 210. A flat spring 250 is positioned at least partially in a space 239 between the second support bar 230 and the base 210. The crowder assembly 200 includes the crowder block 240, and the flat spring 250 positioned at least partially between the crowder block 240 and the base 210. In one or more embodiments, the crowder block 240 is at least partially supported using the flat spring 250 and the second support bar 230. The second support bar 230 can at least partially support the crowder block 240 laterally by the crowder block 240 abutting against the second support bar 230 (such as the recessed edge 234 described below in relation to FIGS. 4 and 5) when the crowder block 240 abuts against one or more panels being hemmed.

The flat spring 250 includes a first end segment 251 coupled to the base 210 (such as by using welding), a second end segment 252 coupled to the crowder block 240 (such as by using hidden screws), and a middle segment 253 (one is shown in FIGS. 2 and 3) extending between the first end segment 251 and the second end segment 252. In one or more embodiments, the first end segment 251 is flat, the second end segment 252 is arcuate, and the middle segment 253 is arcuate. The flat spring 250 includes a strip of sheet metal having a bend 255 with a bend angle BA1. In one or more embodiments, the bend angle BA1 is within a range of 10 degrees to 180 degrees, such as within a range of 20 degrees to 70 degrees. Other values are contemplated for the bend angle BA1. The bend angle BA1 can vary depending, for example, on the material of the flat spring 250, the thickness T1, a height of the flat spring 250, a length of the flat spring 250, and/or a target lifecycle for the flat spring 250.

The bend 255 is a directional bend that changes direction along the Y-axis. In one or more embodiments, the flat spring 250 includes aluminum. Although the flat spring 250 embodiment shown in FIGS. 2 and 3 includes one bend 255, in one or more embodiments additional bends 255 may be formed, as shown in FIGS. 6 and 7, for example. The number of bends 255 is within a range of 1 to 5. In one or more embodiments, the number of bends 255 is within a range of 1 to 3. Other values are contemplated for the number of bends 255. The strip of sheet metal of the flat spring 250 has a thickness T1 that is less than 2.0 mm. In one or more embodiments, the thickness T1 is within a range of 0.3 mm to 1.0 mm, such as about 0.5 mm. The present disclosure contemplates that other values may be used for the thickness T1.

The flat spring 250 biases the crowder block 240 in response to movement of the crowder block 240. The flat spring 250 is configured to limit movement of the crowder block 240 within a movement range MR1 of 0 to 45 mm. In one or more embodiments, the movement range MR1 is limited to have a maximum value within a range of 10 mm to 20 mm. Other values are contemplated for the movement range MR1. The flat spring 250 has a spring constant within a range of 0.01 N/mm to 0.4 N/mm, such as within a range of 0.05 N/mm to 0.4 N/mm. In one or more embodiments, the spring constant is within a range of 0.15 N/mm to 0.2 N/mm. Other values are contemplated for the spring constant. In one or more embodiments, the spring constant is pre-determined by dividing a maximum load by a minimum displacement. The maximum load is the maximum load that the crowder block 240 will undergo during hemming operations (e.g., the maximum load from the rollers). The minimum displacement is the minimum displacement needed for the crowder block 240 during hemming operations (e.g., the minimum displacement needed when a roller rolls over the crowder block 240). The bend 255 is spaced from the first support bar 220 throughout movement of the crowder block 240 over the movement range

MR1. In response to, for example, a roller moving over the crowder block 240, the crowder block 240 is moved down, thereby, compressing the flat spring 250. A lower position 281 for the crowder block 240 and a compressed position 282 for the flat spring 250 are shown as dashed in FIG. 3. After the roller moves past the crowder block 240, the flat spring 250 biases the crowder block 240 up to an upper position shown in solid in FIG. 3.

The crowder block 240 includes a first tapered end 241 and a second end 244 opposing the first tapered end 241. The first tapered end 241 includes a tapered section 242 and a planar section 243. The crowder block 240 is positioned at least partially in an opening 231 formed in the second support bar 230 and is slidable in the opening 231. Using the second support bar 230 and the flat spring 250, the crowder block 240 is retained at least partially in the opening 231. For example, throughout movement of the crowder block 240 over the movement range MR1, the crowder block 240 is retained at least partially in the opening 231 of the second support bar 230. The crowder block 240 moves through the opening 231 and towards the base 210 in response to force applied to the first tapered end 241 of the crowder block 240. For example, a hemming device (such as a roller of a hemming device) moving over the crowder block 240 can apply the force to the first tapered end 241 of the crowder block 240. When the hemming device is no longer applying force to the crowder block 240, the flat spring 250 biases the crowder block 240 back upward through the opening 231.

The crowder block 240 has a block height BL1 (e.g., along the Z-axis) that is larger than a bar height BH1 (e.g., along the Z-axis) of the second support bar 230. The present disclosure contemplates that the bar height BH1 can be referred to as a bar thickness of the second support bar 230. A first portion 246 of the crowder block 240 is positioned on a first side of the second support bar 230, and a second portion 247 of the crowder block 240 is positioned on a second side of the second support bar 230 when the crowder block 240 is at rest, e.g., when no downward force is applied to the crowder block 240.

In one or more embodiments, a first distance D1 between the second support bar 230 and the outer face 211 of the base 210 is greater than a second distance D2 between the first support bar 220 and the front face 212 of the base 210. The present disclosure contemplates that the first distance D1 can be equal to or lesser than the second distance D2. The first distance D1 and the second distance D2 can vary depending, for example, on the shape of the flat spring 250, the thickness T1, and/or a surrounding environment of the crowder assembly 200.

FIG. 4 is a schematic front view of the crowder assembly 200 shown in FIGS. 2 and 3, according to one or more embodiments.

FIG. 5 is a schematic top view of the crowder assembly 200 shown in FIGS. 2-4, according to one or more embodiments.

FIGS. 4 and 5 are described together here.

The crowder block 240 includes a front surface 248 facing away from the base 210. The front surface 248 also faces away from the first support bar 220 and the second support bar 230. The second support bar 230 has a bar width BW1 (e.g., along the X-axis) that is larger than the bar height BH1. The base 210 has a base height BAH1 (e.g., along the Z-axis) and a base width BAW1 (e.g., along the X-axis) that is larger than the bar width

BW1.

The second support bar 230 includes the opening 231 formed in one end 232 of the second support bar 230. The one end 232 of the second support bar 230 includes an outward edge 233 and a recessed edge 234. The opening 231 is a recess formed in the outward edge 233 of the one end 232 to define the recessed edge 234. The crowder block 240 is positioned in the opening 231 of the second support bar 230. The one end 232 of the second support bar 230 partially surrounds an outer perimeter 245 of the crowder block 240. The second support bar 230 does not surround the front surface 248 of the crowder block 240. The crowder assembly 200 is not enclosed such that portions of the crowder assembly 200 are accessible and open to components in the surrounding environment. For example, the first tapered end 241 and the second planar end 244 are not enclosed such that the first tapered end 241 and the second planar end 244 are accessible and open to components in the surrounding environment. As another example, the front surface 248 is not enclosed by the second support bar 230 such that the front surface 248 is accessible (e.g., accessible from a front side along the Y-axis) and open to components in the surrounding environment.

The second support bar 230 includes a pair of tapered edges 235, 236 intersecting the outward edge 233 of the one end 232 in which the opening 231 is formed.

The front surface 248 is coplanar with or disposed outwardly of the outward edge 233 of the second support bar 230. The second support bar 230 has a bar length BL1 (e.g., along the Y-axis) that is larger than the bar width BW1. The base 210 has a base length BAL1 (e.g., along the Y-axis) that is smaller than the bar length BL1.

The tapered section 242 of the crowder block 240 includes a back tapered surface 261 and a pair of side tapered surfaces 262, 263.

Referring back to FIG. 1, the crowder assembly 200 is mounted to the platform 103 such that the crowder block 240 is positioned at least partially in a respective table recess 111 of the plurality of table recesses 111 of the table 110. The base 210 is positioned outside of the respective table recess 111. The base width BAW1 is larger than a recess width RW1 (e.g., along the X-axis) of the respective table recess 111. The vertical position of the crowder assembly 200 can be adjusted. For example, the fasteners can be removed and one or more shims 155 can be inserted between the base 210 and the platform 103 to adjust the vertical position, and the fasteners can be re-inserted through the base 210 and into the platform 103.

FIG. 6 is a schematic axonometric view of an exemplary crowder assembly 600, according to one or more embodiments. The crowder assembly 600 can be used as one or more (such as part or all) of the crowder assemblies of the hemming apparatus 100 shown in FIG. 1. The crowder assembly 600 is similar to the crowder assembly 200 shown in FIGS. 2-5 and includes one or more aspects, features, components, operations, and/or properties thereof.

FIG. 7 is a schematic side view of the crowder assembly 600 shown in FIG. 6, according to one or more embodiments.

FIGS. 6 and 7 are described together here. A flat spring 650 of the crowder assembly 600 includes a first end segment 651 coupled to the base 210, a second end segment 652 coupled to the crowder block 240, and a plurality of middle segments 653 (three middle segments 653 are shown in FIGS. 6 and 7) extending between the first end segment 651 and the second end segment 652. In one or more embodiments, the first end segment 651 is flat, the second end segment 652 is arcuate, and the middle segments 653 are arcuate. The flat spring 650 includes a strip of sheet metal having a plurality of bends 655 with the bend angle BA1. The bends 655 are directional bends that change direction along the Y-axis. The flat spring 650 embodiment shown in FIGS. 6 and 7 includes three bends 655. The strip of sheet metal of the flat spring 250 has the thickness T1.

FIG. 8 is a schematic front view of the crowder assembly 600 shown in FIGS. 6 and 7, according to one or more embodiments.

FIG. 9 is a schematic top view of the crowder assembly 600 shown in FIGS. 6-8, according to one or more embodiments.

Benefits of the present disclosure include increased manufacturing throughput, increased crowder repeatability and reliability, reduced or eliminated crowder clogging, increased crowder lifespans, enhanced dimensional accuracy, reduced cost expenditures, reduced downtime, reduced use of replacement parts, and reduced use of maintenance services.

As an example, the second support bar 230 does not enclose the first tapered end 241, the second planar end 244, or the front surface 248 of the crowder block 240, which facilitates reduced or eliminated debris buildup (e.g., clogging) of the crowder assemblies 200, 600 and reliable biasing of the crowder block 240. The reduced or eliminated clogging facilitates reduced stoppages of manufacturing lines and reduced costs associated with replacement parts and maintenance services. As another example, the flat springs described herein (such as the flat spring 250 and the flat spring 650) facilitate reduced or eliminated clogging, and reliably biasing the crowder block 240 up and down in an inexpensive manner while retaining one or more panels during hemming. It is believed that, using subject matter described herein, the crowder block 240 can undergo 100,000 or more compression cycles (e.g., caused by a roller moving over the crowder block 240) before maintenance is needed for the crowder assembly.

It is contemplated that one or more aspects disclosed herein may be combined.

As an example, one or more aspects, features, components, operations and/or properties of the various embodiments of the hemming apparatus 100, the crowder assembly 200, the flat spring 250, the crowder assembly 600, and/or the flat spring 650, may be combined.

Moreover, it is contemplated that one or more aspects disclosed herein may include some or all of the aforementioned benefits.

While the foregoing is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.

Claims

1. A crowder assembly for manufacturing operations, comprising: a base;a first support bar coupled to the base and extending relative to an outer face of the base;a second support bar coupled to the first support bar and oriented at an angle relative to the first support bar, the second support bar comprising an opening;a crowder block positioned in the opening of the second support bar; anda flat spring comprising: a first end segment coupled to the base, anda second end segment coupled to the crowder block, wherein the flat spring biases the crowder block in response to movement of the crowder block.
2. The crowder assembly of claim 1, wherein the flat spring comprises one or more middle segments extending between the first end segment and the second end segment.
3. The crowder assembly of claim 2, wherein the first end segment is flat, the second end segment is arcuate, and the one or more middle segments are arcuate.
4. The crowder assembly of claim 1, wherein the flat spring includes a strip of sheet metal having one or more bends and a thickness that is less than 2.0 mm.
5. The crowder assembly of claim 1, wherein the flat spring comprises aluminum.
6. The crowder assembly of claim 4, wherein the one or more bends are spaced from the first support bar.
7. The crowder assembly of claim 1, wherein the opening is a recess formed in one end of the second support bar.
8. The crowder assembly of claim 7, wherein the second support bar is spaced from the base, the one end of the second support bar partially surrounds an outer perimeter of the crowder block, and the flat spring is positioned at least partially in a space between the second support bar and the base.
9. The crowder assembly of claim 7, wherein the second support bar further comprises a pair of tapered edges intersecting the one end.
10. The crowder assembly of claim 5, wherein the crowder block: comprises a first tapered end,comprises a second end opposing the first tapered end, andmoves through the opening and towards the base in response to force applied to the first tapered end of the crowder block.
11. The crowder assembly of claim 1, wherein the crowder block has a block height that is larger than a bar height of the second support bar.
12. The crowder assembly of claim 11, wherein a first portion of the crowder block is positioned on a first side of the second support bar, and a second portion of the crowder block is positioned on a second side of the second support bar.
13. The crowder assembly of claim 11, wherein the crowder block comprises a front surface facing away from the base, and the front surface is coplanar with or disposed outwardly of an outward edge of the second support bar.
14. The crowder assembly of claim 13, wherein the second support bar does not enclose the front surface of the crowder block, thereby, leaving the front surface open to a surrounding environment.
15. The crowder assembly of claim 11, wherein: the second support bar has a bar width that is larger than the bar height, and a bar length that is larger than the bar width; andthe base has a base height, a base width that is larger than the bar width, and a base length that is smaller than the bar length.
16. A hemming apparatus for manufacturing operations, comprising: a table comprising a plurality of table recesses formed in a plurality of table surfaces; anda plurality of crowder assemblies aligning with the plurality of table recesses, at least one crowder assembly of the plurality of crowder assemblies comprising: a base positioned outwardly of a respective table recess of the plurality of table recesses,a first support bar coupled to the base and extending relative to an outer face of the base,a second support bar coupled to the first support bar and oriented at an angle relative to the first support bar, the second support bar comprising an opening,a crowder block positioned in the opening of the second support bar, anda flat spring positioned at least partially between the crowder block and the base.
17. The hemming apparatus of claim 16, wherein the base has a base height, a base width that is larger than a recess width of the respective table recess, and a base length.
18. The hemming apparatus of claim 17, wherein the crowder block is positioned in the respective table recess, and the second support bar extends into the respective table recess.
19. The hemming apparatus of claim 18, wherein the second support bar further comprises a pair of tapered edges intersecting one end in which the opening is formed.
20. The hemming apparatus of claim 19, wherein the pair of tapered edges are positioned at least partially in the respective table recess.

CROWDER ASSEMBLIES, HEMMING APPARATUS, AND RELATED COMPONENTS FOR MANUFACTURING OPERATIONS

Information

Publication Number

Date Filed

Date Published

Inventors

Original Assignees

CPC

International Classifications

Abstract

Description

Claims