Patent Application
20240149329
The present disclosure relates generally to systems and methods for forming and installing retaining rings. More specifically, the present disclosure relates to an on-demand method and system for forming retaining rings as needed for installation in a manufactured assembly.
Conventional solutions for assembling retaining rings may include forming a length of wire using a die. Retaining rings are typically manufactured separately from their installation in a manufactured assembly, such as a damper tube for a shock absorber.
Shipping density and storage of retaining rings can cause variation of dimensions. Detangling, aligning, loading and gaging of retaining rings on mandrels prior to installation can be very labor intensive. Automated singulation and alignment of retaining rings requires precise escapement and gripper alignment for retainer rings in an unconstrained state. Furthermore, once the retainer rings are in an unconstrained state, flatness, roundness and/or orientation may need to be re-established during material handling.
The present disclosure provides a method for forming and installing a retaining ring. The method comprises: feeding a wire in a linear path into a forming die having a circular bore; forming, using the forming die, the wire into a formed ring having a ring shape; transferring the formed ring from the forming die to a transfer puck; and installing the formed ring, as a retaining ring, in a tube of a product assembly. The formed ring is maintained in a constrained state between forming in the forming die and installation in the product assembly.
The present disclosure also provides a system for forming and installing a retaining ring into a product assembly. The system includes a forming die configured to form a wire into a formed ring having a ring shape; and a transfer puck configured to transfer the formed ring from the forming die. The system is configured to maintain the formed ring in a constrained state between forming in the forming die and installation in a product assembly.
The present disclosure also provides a system for forming and installing a retaining ring into a product assembly. The system includes a forming die configured to form a wire into a formed ring having a ring shape. The system also includes a tubular die configured to cooperate with a roller mandrel to form the formed ring into the retaining ring; and a transfer puck configured to transfer the formed ring from the forming die to the tubular die. The transfer puck includes a tapered groove configured to align the transfer puck with at least the forming die.
Further details, features and advantages of designs of the invention result from the following description of embodiment examples in reference to the associated drawings.
Referring to the drawings, the present invention will be described in detail in view of following embodiments.
The present disclosure pertains to a system and process for on-demand or Just-in-Time (JIT) forming and installation of retainer rings. Such retainer rings may be used for retaining structures within a tubular assembly. The retainer ring forming and installation process may be implemented to form and install retainer rings for holding valve assemblies in a damper tube for a suspension damper assembly. However, the retainer ring forming and installation process of the present application may be applied to other assemblies, such as brake boosters, etc.
The forming process illustrated on
The assembly tool 60 may be configured to transfer the retaining rings 10e into the main tube 82 of the damper tube 80 while maintaining the retaining rings 10e in constrained state. The constrained state may include the retaining rings 10e being partially or completely annularly surrounded for holding the retaining rings in a fixed location and orientation.
The method 100 includes feeding a wire in a linear path into a forming die at step 110. Step 110 may include feeding a segment of wire 10a through the tangential aperture 24 and into the forming die 20 of the forming assembly 30. In some embodiments, the wire may include a pre-cut segment of wire. Alternatively, the wire may be an extended length that may be cut after being fed into the forming die. A bulk feeder (not shown in the Figures), such as a wire feed hopper capable of holding numerous pre-cut segments of wire 10a, which may be mechanically aligned and positioned with of the forming assembly 30. In some embodiments, a bulk feeder can be reloaded with additional pre-cut segments of wire 10a without interrupting the process of forming and installing the retaining rings.
The method 100 also includes forming the wire into a formed ring having a ring shape at step 112. Step 112 may include using forming assembly 30 for producing the formed ring 10d. The forming assembly 30 may employ a push die, which may be translated linearly by a dove tail slide (not shown in the Figures). Step 112 may include a pre-cut segment of wire being loaded into a machine breech similar to a bolt action rifle. Step 112 may employ pusher force low enough to utilize a 1.4 mm-diameter pusher pin and allow wire to wrap around tooling inside diameter (ID). The 1.4 mm pusher pin is merely an example, and the pusher pin may be larger than 1.4 mm in diameter or smaller than 1.4 mm in diameter. The pusher pin should have a size and/or material characteristics that are suited for a given size and type of the wire to be formed. The pusher pin may be sufficiently rigid and/or supported against bending so as to remain straight as the wire is formed to the ring shape.
The method 100 also includes transferring the formed ring from the forming die to a transfer puck at step 114. The transfer puck may include a circular bore that encircles the ring and retains the ring thereto.
The method 100 also includes transferring the formed ring the formed ring from the transfer puck to a tubular die at step 116.
The method 100 also includes forming, using a roller mandrel and the tubular die, the formed ring into the retaining ring at step 118. Step 118 may include forming the retaining ring to a finished dimension.
The method 100 also includes transferring the retaining ring from the tubular die to an assembly tool at step 120. Step 120 may include using the transfer assembly 50 to transfer the retaining ring 10e from the tubular die 44 and into the assembly tool 60.
The method 100 also includes installing the formed ring, as a retaining ring, in a tube of a product assembly at step 122. The product assembly may include, for example, the damper tube 80 for a shock absorber.
In some embodiments, the formed ring is maintained in a constrained state between forming in the forming die and installation in the product assembly. In other words, the formed ring may be retained around a peripheral edge and never allowed to be in a free or unrestrained state. The retainer ring may, therefore, be confined to a round, flat configuration through the entire process of finishing, transfer, and installation.
In some embodiments, the forming and installing of the retaining ring at steps 112 through 122 are performed on-demand, proximate in location and in quick succession. For example, steps 112 through 122 may be performed by equipment located in close proximity and without requiring the retaining ring 10e to be transported by more than a few meters. Steps 112 through 122 may be performed in quick succession, no more than a few seconds therebetween. In some embodiments, steps 112 through 122, including forming and installing the retaining ring 10e may be performed within a fraction of a second.
Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
