Patent Application
20240316612
A tapping sensor assembly including a magnet and magnetic sensor for determining the position of a tapping head.
Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments can take various and alternative forms. The figures are not necessarily to scale. Some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the embodiments of the present invention. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.
Moreover, except where otherwise expressly indicated, all numerical quantities in this disclosure are to be understood as modified by the word “about” in describing the broader scope of this disclosure. Practice within the numerical limits stated is generally preferred. Also, unless expressly stated to the contrary: percent, “parts of,” and ratio values are by weight. The term “polymer” includes “oligomer,” “copolymer,” “terpolymer,” and the like. The description of a group or class of materials as suitable or preferred for given purpose implies the mixtures of any two or more of the members of the group or class are equally suitable or preferred. Molecular weights provided for any polymers refers to number average molecular weight. A description of constituents in chemical terms refers to the constituents at the time of addition to any combination specified in the description and does not necessarily preclude chemical interactions among the constituents of a mixture once mixed. The first definition of an acronym or other abbreviation applies to all subsequent uses herein of the same abbreviation and applies mutatis mutandis to normal grammatical variations of the initially defined abbreviation. Unless expressly stated to the contrary, measurement of a property is determined by the same technique as previously or later referenced for the same property.
This disclosure is not limited to the specific embodiments and methods described below, as specific components and/or conditions may vary. Furthermore, the terminology used herein is used only for the purpose of describing particular embodiments and is not intended to be limiting in any way.
The term “substantially” or “generally” may be used herein to describe disclosed or claimed embodiments. The term “substantially” or “generally” may modify a value or relative characteristic disclosed or claimed in the present disclosure. In such instances, “substantially” or “generally” may signify that the value or relative characteristic it modifies is within +0%, 0.1%. 0.5%, 1%, 2%, 3%, 4%, 5% or 10% of the value or relative characteristic.
It should also be appreciated that integer ranges explicitly include all intervening integers. For example, the integer range 1-10 explicitly includes 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10. Similarly, the range 1 to 100 includes 1, 2, 3, 4 . . . 97, 98, 99, 100. Similarly, when any range is called for, intervening numbers that are increments of the difference between the upper limit and the lower limit divided by 10 can be taken as alternative upper or lower limits. For example, if the range is 1.1. to 2.1 the following numbers 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, and 2.0 can be selected as lower or upper limits.
Referring to
In one or more embodiments, the tapping assembly 104 defines, cuts, punches, or drills a hole/orifice through the component 10. In still other embodiments, the tapping assembly 104 deforms the component 10 without necessarily piercing it. In other words, the tapping assembly 104 may or may not define a hole/orifice. The tapping assembly 104, as shown in
In a variation, the actuator 114 is at least partially extending beyond the outer housing 110. In a refinement, the actuator 114 and the cavity 112 include a first portion and a second portion that may be sized differently such that the second portion 113 of the actuator can only translate within the second portion of the cavity (so the actuator 114 can actuate without being complete discharged from the outer housing 110), while the first portion 111 of the actuator 114 can translate in both the first portion and second portion of the cavity.
In various embodiments, the actuator 114 includes/cooperates with a receiving head 116 configured to receive a tapping head 123. In various embodiments, the tapping head 123 deforms the component 10. In a variation, the tapping head 123 is received through the component 10. For example, the receiving head 116 is arranged such that it is aligned with the tapping head 123. Alternatively, the receiving head 116 may receive the component 10 when a hole or orifice is not defined within the component 10. In a refinement, the receiving head 116 includes a tip 121. For example, the tip 121 may be mounted to the receiving head 116. In one or more embodiments, the receiving head 116 rotates to reduce the wear and tear because the tapping head 123 also actively rotates while tapping the component 10. For example, the receiving head 116 is attached to the actuator 114 via a bearing 115, or any other suitable pivoting mechanism. For example, an annular bearing 115 is disposed around a portion of the actuator 114 and/or between the actuator 114 and the receiving head 116. In a variation, a wear bushing 117 cooperates with the actuator 114 and the bearing 115. For example, the wear bushing 117 is disposed between the actuator 114 and the bearing 115. In various embodiments, the tapping head 123 rotates to facilitate deforming the component 10. In one or more embodiments, the receiving head 116 and/or tip 121 are made of a more durable material than the actuator 114 and/or outer housing 110. For example, the receiving head 116 and tip 121 are steel or stainless steel.
In various embodiments, the sensor assembly 105 includes a magnetic sensor 108 and a magnet 106 that triggers and/or activates the magnetic sensor 108. In a refinement, the magnetic sensor 108 and magnet 106 cooperate to detect/determine the position of the actuator 114 relative to the housing 110. For example, the magnet 106 triggers and/or activates the magnetic sensor 108 when aligned (or alternatively when misaligned) such that the position of the actuator 114 (and receiving head 116/tapping head 123) is known relative to the housing 110. In various embodiments, the tapping head 123 is retracted when the magnet 106 triggers and/or activates the magnetic sensor 108. For example,
In a refinement, the first position is a retracted/compressed position, and the second position is an extended position (or vice versa). In one or more embodiments, the magnetic sensor 108 is disposed on or embedded in the housing 110 or actuator 114 and the magnet 106 is disposed on or embedded in the other of the housing 110 or actuator 114. Thus, when the actuator 114 moves/translates through the cavity, the magnet 106 triggers or activates the magnetic sensor 108 such as when in alignment (or out of alignment), which signals that it is time to retract the actuator 114. In various embodiments, the outer housing 110 and the actuator 114 are co-axial such that the actuator 114 translates along a shared axis of the outer housing 110 and the actuator 114. In a variation, the tapping head 123 is also coaxial with the actuator 114 and/or the outer housing.
In various embodiments, the magnetic sensor 108 is in communication with an electrical circuit (not shown) which may include a controller to operate actuation (e.g., discharge and retraction) of the tapping head 123. In a refinement, the electrical circuit powers the magnetic sensor 108. In a variation, the magnetic sensor 108 is in communication with the electrical circuit via a wired connection or alternatively a wireless connection such as through radio frequency or electromagnetic communication (e.g., WIFI or Bluetooth). The wireless connection should not interfere with the magnet 106 and magnetic sensor 108. In a variation, a solid-state sensor is used. The magnet-magnetic sensor arrangement does not produce false-positives that are typical of conventional inductive proximity sensors, which may produce false-positives from metal shaving and thus require constant maintenance during long periods of operation. The magnetic arrangement thus requires less maintenance and withstands longer periods of operation.
In various embodiments, the sensors assembly 105 defines a fluid passage 130 that provides a fluid such as a tapping fluid/lubricant to the tip 121 (or the contact point between the receiving head 116 and the tapping head 123. In a variation, the fluid passage 130 is pressurized to deliver the fluid. In a refinement, the fluid passage 130 extends from a first end 132 of the sensor assembly 105 to a second end 134 of the sensor assembly 105. In one or more embodiments, the fluid passage 130 is centrally located throughout the sensor assembly 105. For example, the actuator 114, receiving head 116, and tip 121 define a passage such as a central hollow passage. This provides the tapping fluid/lubricant to the tapping head 116 and tip 121 during operation, which reduces wear and tear of the tapping head 116 and/or tip 121. In various embodiments, the central hollow passage of the actuator 114 is also co-axial with the cavity 112 of the outer housing 110.
Referring to
In various embodiments, the end opposite the receiving head 116 cooperates with an actuating mechanism (e.g., a spring) to align (or alternatively misalign) the magnet 106 and magnetic sensor 108. Thus, when the receiving head 116 receives the tapping head 123, such that it the actuates the actuator 114, it misaligns (or alternatively aligns) the magnet 106 and magnetic sensor 108. For example, the second section 119 cooperates with the actuating mechanism 120 (i.e., the second section 119 is disposed in and cooperates with a spring) such that the actuating mechanism 120 applies a force to the actuator 114 in a direction towards the tapping head 123.
In one or more embodiments, the bearing 115, the wear bushing 117, at least a portion of the first section 118, the magnet 106, at least a portion of the second section 119, the spring 120 or a combination thereof is disposed in the outer housing 110. In a variation, a protective sleeve 122 is disposed over the outer housing 110 and the magnetic sensor 108 is disposed between the protective sleeve 122 and the outer housing 110. In various embodiments, the outer housing 110 cooperates with mounting components 124 such as mounting flanges/nuts. For example, the mounting flanges/nuts are locking nuts disposed at opposite ends of the outer housing 110. In a refinement, a mounting flange is disposed at the end most proximate the receiving head 116 and a nut is disposed on the end opposite the receiving head 116.
In still other embodiments, the die assembly 100 and/or tapping assembly 104 include a controller (i.e., a non-transitory computer readable medium having computer executable code thereon that is executed by a processor to perform various tasks). The controller (not shown) cooperates with the die assembly 100, tapping assembly 104, die/mold 102, and/or magnetic sensor 108 for operation such as to actuate and/or retract the tapping head 123 when the magnet 106 activates or triggers the magnetic sensor 108. In various embodiments, the controller performs various other task such as robotic delivery of the component 10, and/or actuating the compressive force of the die/mold 102 to shape the component 10.
In one or more embodiments, the controller includes or is in communication with one or more processors and memory. The one or more processors including one or more devices selected from high-performance computing systems including high-performance cores, microprocessors, micro-controllers, digital signal processors, microcomputers, central processing units, field programmable gate arrays, programmable logic devices, state machines, logic circuits, analog circuits, digital circuits, or any other device that manipulate signals (analog or digital) based on computer-executable instructions residing in the memory. In variations, the memory includes a single memory device or a number of memory devices including, but not limited to, random access memory (RAM), volatile memory, non-volatile memory, static random access memory (SRAM), dynamic random access memory (DRAM), flash memory, cache memory, or any other device capable of storing information. In a refinement, the non-volatile memory/storage includes one or more persistent data storage devices such as a hard drive, optical drive, tape drive, non-volatile solid state device, cloud storage or any other device capable of persistently storing information.
In one or more embodiment, the executable code/instructions reside in a software module. In a refinement, the software module includes operating systems and applications. In various embodiments, the software module is compiled or interpreted from a computer program created using a variety of programming languages and/or technologies, including, without limitation, and either alone or in combination, Java, C, C++, C#, Objective C, Fortran, Pascal, Java Script, Python, Perl, and PL/SQL. Non-volatile storage may also include data supporting the functions, features, calculations, and processes.
In some embodiments, the systems described above include computer readable storage media, which is inherently non-transitory, and in various refinements includes volatile or non-volatile, and removable and non-removeable tangible media implemented in any method or technology for storage of information, such as computer-readable instructions, data structures, program modules, or other data. In a variation, computer readable storage media further includes RAM, ROM, erasable programmable read-only memory (EPROM), electrically erasable programmable read-only memory (EEPROM), flash memory or other solid state memory technology, portable compact disc read-only memory (CD-ROM), or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store the desired information and which can be read by a computer. In various embodiments, the computer readable program instructions may be downloaded to a computer, another type of programmable data processing apparatus, or another device form of a computer readable storage medium or to an external computer or external storage device via a network.
In one or more embodiments, the computer readable program instructions stored in a computer readable medium may be used to direct a computer, other types of programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions that implement functions, acts, and/or operations described herein. The functions, acts, and/or operations described herein may be re-ordered, processed serially, and/or processed concurrently.
Referring to
The unshaped or raw component is not particularly limited and may, for example, be sheet metal. The unshaped or raw component is not necessarily limited to a completely unshaped component but instead may be a component that merely requires additional shaping. In various embodiments, positioning includes disposing the unshaped or raw component in one of the die assemblies described herein such that it is adjacent the die or mold. In a refinement, the component is robotically positioned in the die assembly such as by one or more robotic arms. In various embodiments, shaping involves applying pressure to the unshaped component (i.e., compressing the unshaped or raw component) such that it is pressed into and contacts the die/mold to adopt a predetermined shape such as the shape of the die or mold, i.e., forming a shaped component.
Tapping involves deforming, piercing, cutting, and/or punching the component. In various embodiments, shaping and tapping may occur simultaneously. In a refinement, tapping may occur immediately before or after shaping such that shaping and tapping occur in a single step. In one or more embodiments, tapping occurs by engaging the tapping head of a tapping assembly with the component such as by contacting it. In various embodiments, the tapping head protrudes through the component to engage a sensor assembly of the tapping assembly such that a magnet triggers/activates a magnetic sensor. Upon activation the tapping head is retracted. Alternatively, the tapping head deforms the component which then engages the sensor assembly. In various embodiments, the component is disposed between the tapping head and the receiving head of the sensor assembly prior to tapping (i.e., the tapping head and receiving head are disposed on opposite sides of the component). In one or more embodiments, the tapping head actuates the actuator of the sensor assembly when it is received by the receiving head. In a variation, actuation includes translating the actuator from the first position to the second position such that the magnet trigger/activates the magnetic sensor. In various embodiments, the tapping head is rotated during tapping and engages a rotatable receiving head to reduce wear and tear. In a refinement, a fluid such as a tapping fluid/lubricant is applied through a fluid passage to reduce the wear and tear on the tip of the receiving head and/or tapping head. The die assembly and in-die tapping assembly provide a shaped and tapped component having one or more orifice.
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.
According to a first aspect of the die assembly described herein, the die assembly includes a die, and a tapping assembly comprising a tapping head and a sensor assembly. The tapping assembly cooperates with the die to shape a component. The sensor assembly comprises a magnetic sensor, and a magnet. The sensor assembly includes an outer housing and an actuator. The outer housing includes a hollow body defining a cavity sized to at least partially receive the actuator. The actuator includes a tip arranged to cooperate with the tapping head. The magnet or magnetic sensor is disposed along the outer housing and the other of the magnet or magnetic sensor is disposed such that when the actuator is actuated in the cavity by the cooperating with the tapping head it aligns or misaligns the magnet and magnetic sensor to trigger or activate the magnetic sensor.
According to a second aspect, the tip of the first aspect or any of the following aspects is rotatable.
According to a third aspect, the housing and actuator of any of the prior or subsequent aspects include a non-magnetic material or is a non-magnetic material.
According to a fourth aspect, the magnet of any of the prior or subsequent aspects is arranged on the actuator.
According to a fifth aspect, the actuator of any of the prior or subsequent aspects defines a fluid passage to deliver a fluid from a first end of the sensor assembly to a second end of the sensor assembly such that the tip is lubricated while cooperating the tapping head.
According to a sixth aspect, the die assembly of any of the prior or subsequent aspects includes a controller configured to retract or actuate the tapping head when the magnet triggers or activates the magnetic sensor.
According to a seventh aspect, the tapping head of any of the prior or subsequent aspects deforms a component during operation.
According to an eighth aspect, the tapping head of any of the prior or subsequent aspects pierces a component during operation.
According to a ninth aspect, the sensor assembly of any of the prior or subsequent aspects includes a hollow body defining a cavity, an actuator at least partially disposed in the cavity, a magnet, and a magnetic sensor. The actuator comprising a rotatable receiving head for cooperating with a tapping head of a tapping assembly. The magnet or magnetic sensor is arranged along the actuator and the other of the magnet or magnetic sensor is arranged along the hollow body such that when the actuator moves from a first position to a second position in the hollow body, the magnet activates the magnetic sensor indicating the position of the actuator relative to the hollow body.
According to a tenth aspect, the receiving head of any of the prior or subsequent aspects receives a tapping fluid through a fluid passage defined in the actuator.
According to an eleventh aspect, the hollow body comprises a first material and the actuator comprises a second material that is different from the first material.
According to a twelfth aspect, the first material of any of the prior or subsequent aspects is brass and/or the second material of any of the prior or subsequent aspects is aluminum.
According to a thirteenth aspect, the receiving head of any of the prior or subsequent aspects is arranged to cooperate with the tapping head such that the actuator is actuated from the first position to the second position or vice versa.
According to a fourteenth aspect, a method of making a part comprises positioning an unshaped component in a die assembly, shaping the unshaped component with the die assembly, and tapping the component with a tapping assembly of the die assembly. The unshaped component is positioned adjacent a mold of the die assembly. The unshaped component is shaped by applying pressure to the unshaped component such that it contacts the mold to form a shaped component. Tapping is carried out with a tapping assembly that comprises a tapping head that cooperates with a sensor assembly. The sensor assembly comprises an actuator with a receiving head arranged to cooperate with the tapping head. The actuator comprises a magnet such that when the tapping head is received by the receiving head it actuates the actuator and the magnetic activates the magnetic sensor.
According to fourteenth aspect, the tapping head and sleeve of any of the prior or subsequent aspects are disposed on opposite sides of the component prior to tapping the component.
According to a fifteenth aspect, the (unshaped) component of any of the prior or subsequent aspects is disposed between the tapping head and the receiving head.
According to a sixteenth aspect, tapping of any of the prior or subsequent aspects occurs during shaping.
According to a seventeenth aspect, the receiving head of any of the prior or subsequent aspects is rotatable.
According to an eighteenth aspect, the method of any of prior or subsequent aspects comprises receiving a tapping fluid at the receiving head through a fluid passaged defined in the actuator.
According to a nineteenth aspect, the magnet of any of the prior or subsequent aspects activates the magnetic sensor when the magnet and magnetic sensor are aligned.
According to a twentieth aspect, the shaped component of any of the prior or subsequent aspects is an automotive component.
According to a twenty-first aspect, the sensor of any of the prior or subsequent aspects is a solid-state sensor.
