CA2598137C - System and method for staking an assembly of components with compensation for component tolerances - Google Patents
System and method for staking an assembly of components with compensation for component tolerances Download PDFInfo
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- CA2598137C CA2598137C CA 2598137 CA2598137A CA2598137C CA 2598137 C CA2598137 C CA 2598137C CA 2598137 CA2598137 CA 2598137 CA 2598137 A CA2598137 A CA 2598137A CA 2598137 C CA2598137 C CA 2598137C
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01M—TESTING STATIC OR DYNAMIC BALANCE OF MACHINES OR STRUCTURES; TESTING OF STRUCTURES OR APPARATUS, NOT OTHERWISE PROVIDED FOR
- G01M99/00—Subject matter not provided for in other groups of this subclass
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Abstract
A novel method and system is provided for staking components in a mechanical device to achieve a resulting staked device with at least one desired inter- component clearance independent of feedstock variations in the materials used to form the components. Variants are fabricated for at least one of the pair of stacking dies used in the staking press and the variant with an appropriate staking clearance is selected each time a batch of components changes. In this manner, variations between lots of feedstock materials used to form the components will not result in staked devices which suffer from lateral looseness or other staking results which do not meet the specifications for the device. In a second embodiment, devices are first staked in a conventional staking press and are then loaded into a clearance setting press which deforms at least a portion of the staked device to obtain the desired clearance. By carefully limiting the force with which the deformation is performed, the desired clearance can be obtained without requiring the batching of components in the manufacturing process.
Description
System and Method For Staking An Assembly Of Components Wit Compensation For Comaonent Tolerances FIELD OF THE INVENTION
[0001] The present invention relates to a system and method for staking an assembly of components in a mechanical device. More specifically, the present invention relates to a system and method of staking one or more components in a mechanical device to another component in the device whereby looseness of components in the resulting assembled device can be reduced, independent of tolerances in the assembly materials.
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a system and method for staking an assembly of components in a mechanical device. More specifically, the present invention relates to a system and method of staking one or more components in a mechanical device to another component in the device whereby looseness of components in the resulting assembled device can be reduced, independent of tolerances in the assembly materials.
BACKGROUND OF THE INVENTION
[0002] It is known to make devices from assemblies of mechanical components, which are not expected to be disassembled, by staking the components together.
Generally, one or more of the mechanical components will include at least one portion (the "staking material") which is permanently deformed during the staking process to fix (i.e. "stake") the components together.
The compressive forces of the staking process are applied to the assembly of mechanical components via a pair of appropriately shaped dies to bend, curl, mushroom or otherwise permanently deform the staking material to fasten the components together to form the device.
Generally, one or more of the mechanical components will include at least one portion (the "staking material") which is permanently deformed during the staking process to fix (i.e. "stake") the components together.
The compressive forces of the staking process are applied to the assembly of mechanical components via a pair of appropriately shaped dies to bend, curl, mushroom or otherwise permanently deform the staking material to fasten the components together to form the device.
[0003] Staking provides several advantages over other assembly techniques such as bolts or welding, in that it is relatively inexpensive, requires little volume within the assembly (unlike bolts or screws which require volume in the assembly to receive the threaded portion of the bolt or screw) and results in a permanent connection of the assembly into the device.
[0004] However, staking also suffers from disadvantages. When a device is assembled by staking, the tolerances of the components in the staked device can result in some looseness of the components in the device, even though the device housing is staked, allowing one or more of the components to move with respect to others. When subjected to mechanical vibration, the loose component or components can move, resulting in undesired noises being created in the device. In particular, in the automotive industry, these noises are often referred to as Buzz, Squeak and Rattle ("BSR") and are very undesirable.
[ooos] Previous attempts to reduce undesired looseness by tighten tolerances on the feedstock materials have resulted in an unacceptable increase in manufacturing costs. Other attempts to mitigate the symptoms of the undesirable looseness, such as BSR, have included adding elastomeric materials to the staked devices but such materials also increase manufacturing costs and may have unacceptably short lifetimes within the devices.
[0006] It is desired to have a method for staking an assembly of components in a mechanical device which can avoid undesired looseness of components in the staked device.
SUMMARY OF THE INVENTION
[0007) It is an object of the present invention to provide a novel system and method for staking an assembly of components in a mechanical device which obviates or mitigates at least one disadvantage of the prior art.
[0008] According to a first aspect of the present invention, there is provided a method of method for staking an assembly of components in a mechanical device comprises the steps of:
(i) forming at least one test device using a pair of staking dies in a press;
(ii) examining the at least one test device to determine if a clearance between components in the device has been properly achieved; (iii) if the clearance has not been properly achieved, changing at least one of the pair of staking dies in the press and restarting the method at step (i);
(iv) if the clearance has been properly achieved, producing devices with the pair of staking dies; and (v) restarting the method at step (i) if a batch change occurs to any component being staked in the device wherein a dimensional change in the changed component could affect the clearance.
[00091 Preferably, step (iii) comprises determining whether the clearance of the at least one test device was too large or too small and, if too small, changing at least one of the pair of dies to increase the clearance of the dies, or, if too large, changing at least one of the pair of dies to decrease the clearance of the dies.
[0010] According to another aspect of the present invention, there is provided a method for staking an assembly of components in a mechanical device wherein the resulting devices have a pre-selected clearance between two or more components, comprising the steps of: (i) loading the components into a staking press and staking the components to form a staked device; (ii) loading the staked device into a clearance setting press comprising a support on which the device rests and a compression die attached to a ram, the compression die being operable to engage a portion of the staked device to deform the portion of the device to set the pre-selected clearance; and (iii) moving the ram to bring the compression die into contact with the portion of the device with a pre-selected force to deform the portion to set the pre-selected clearance.
[0011] The present invention provides a novel method for staking components in a mechanical device to achieve a resulting staked device with at least one desired inter-component clearance independent of feedstock variations in the materials used to form the components.
Variants are fabricated for at least one of the pair of stacking dies used in the staking press and the variant with an appropriate staking clearance is selected each time a batch of components changes. In this manner, variations between lots of feedstock materials used to form the components will not result in staked devices which suffer from lateral looseness or other staking results which do not meet the specifications for the device. In a second embodiment, devices are first staked in a conventional staking press and are then loaded into a clearance setting press which deforms at least a portion of the staked device to obtain the desired clearance. By carefully limiting the force with which the deformation is performed, the desired clearance can be obtained without requiring the batching of components in the manufacturing process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Preferred embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:
Figure 1 shows an exploded view of a disc recliner for an automotive seat back which can be manufactured in accordance with the present invention;
Figure 2 shows a partial section through a staked disc recliner of Figure 1;
Figure 3 shows a cross sectional view of a portion of a staking press in accordance with the method of the present invention with the press open and loaded with a set of components for the disc recliner of Figure 1;
Figure 4 shows a similar cross sectional view to that of Figure 3 with the press closed to stake the upper and lower components of the device together;
Figure 5 shows a side cross section of an upper die useful in the press of Figure 2;
Figure 6 shows a perspective view of the die of Figure 5; and Figure 7 shows a portion of side cross section of three upper dies which can be employed with the press of Figure 2.
DETAILED DESCRIPTION OF THE INVENTION
[0013] While the following discussion of the system and method of the present invention makes reference to the staking of a specific device, specifically a known disc recliner, as an example of a device which can be advantageously manufactured with the system and method of the present invention, the present invention is not limited to use in manufacturing this disc recliner or any other specific device. Instead, the present invention can be advantageously employed to manufacture a wide variety of devices as will occur to those of skill in the art.
[0014] As mentioned above, a known disc recliner is indicated generally at 20 in Figure 1.
Devices such as disc recliner 20 are commonly employed to provide for the positioning of an automotive seat back with respect to the set base.
[0015] As shown in the Figure, disc recliner 20 comprises a guide plate 24, which can be attached to a seat base, and a tooth piate 28 which can be attached to a seat back. A set of pawls 32 are located within guide plate 24 and are biased by a spring 36 to lock the angular position of tooth plate 28 with respect to guide plate 24 by engaging a set of teeth located about the inner peripheral lip of tooth plate 28. A shaft 40 includes a cam 44 which is located within set of pawls 32. Finally, a retainer ring 48 is staked to guide plate 24, enclosing the other components of disc recliner 20, to complete assembly of disc recliner 20.
[0016] When it is desired to alter the angular position of tooth plate 28 with respect to guide plate 24, thus altering the position of the seat back with respect to the seat base, a lever (not shown) attached to shaft 40 is moved, rotating shaft 40 and bringing the cam surfaces of cam 44 into contact with the set of pawls 32.
[0017] Cam 44 moves pawls 32 out of contact with the teeth of tooth plate 28, against the biasing force of spring 36, which allows relative angular movement between tooth plate 28 and guide plate 24.
[0018] When the seat back is positioned as desired, the lever is released and cam 44 allows set of pawls 32 to reengage the teeth of tooth plate 28 under the bias force of spring 36, thus again fixing the angular position of tooth plate 28 with respect to guide plate 24 and the seat back with respect to the seat base.
[0019] As shown in Figure 2, when retainer ring 48 is staked to guide plate 24, a clearance 60 must be provided between tooth plate 28 and the radial upper surface 64 of retainer ring 48 to allow tooth plate 28 to rotate with respect to guide plate 28 and retainer ring 48 when set of pawls 32 are disengaged from tooth plate 28.
[0020] While clearance 60 must be sufficient to allow for rotation of tooth plate 28, if clearance 60 is excessive, tooth plate 28 will be capable of excessive movement within disc recliner 20 and can thus produce undesired BSR noise. Accordingly, control of clearance 60 is important to avoid undesired BSR noise while still permitting correct operation of disc recliner 20.
[0021] As mentioned above, the present invention is not limited to the manufacture of disc recliners 20, or the like, and many other staked devices have similar issues with clearances between components and the present invention can advantageously be employed in the manufacture of such devices.
[0022] Figure 3 shows a staking press 100, used in a method in accordance with the present invention. Press 100 can be generally conventional and preferably includes a base portion 104, to which a lower die 108 is affixed, and which also preferably includes a locator 112 which assists in loading and aligning the components to be staked by press 100.
[0023] In the illustrated embodiment, disc recliner 20 being staked by press 100, but as mentioned above a variety of other devices can be staked in accordance with the present invention.
[00241 Press 100 further includes a ram 116 to which an upper die 120, an example of which is best seen in Figures 5 and 6, is mounted. Upper die 120 includes a cavity 124 with an appropriate shape and volume to receive the upper portion of disc recliner device 20 when upper die 120 is brought into contact with lower die 108 as press 100 is cycled.
(00251 In the illustrated embodiment, much like a conventional staking operation, guide plate 24 of disc recliner device 20 rests on lower die 108 with the remaining components of disc recliner 20 resting atop it. Press 100 is then closed, with retainer ring 48 being received in cavity 124 and the lower edge of retainer ring 48 engages lower die 108 which folds the lower edge over and onto the edge of the lower side of guide plate 24 to stake disc recliner device 20 together as shown in Figures 2 and 4.
[0026] However, unlike known staking presses and methods, upper die 120 further includes a first compression surface 136 and second compression surface 132 which engage the upper radial surface 64 of retainer ring 48 as press 100 is closed, such that upper radial surface 64 is compressed downward to reduce clearance 60.
(0027] Upper die 120 further includes an abutment surface 136 which abuts a corresponding abutment surface on lower die 108 to stop the closing of press 100 when upper die 120 and lower die 108 are fully closed and to thus prevent over compression of upper radial surface 64 of retainer ring 48.
[0028] First compression surface 136 and second compression surface 132 are vertically spaced in upper die 120 at a specified distance which is selected such that the deformation of upper radial surface 64 will result in a desired clearance 60. This vertical spacing is determined, as is known to those of skill in the art, by the design of upper die 120, the relative distances between first compression surface 136 and second compression surface 132, the thickness of the material from which retainer ring 48 is formed and the vertical height of the components of disc recliner device 20 loaded into press 100 for staking.
[0029] Once the correct vertical spacing has been determined and upper die 120 fabricated, changes in the thicknesses of components of disc recliner device 20, such as changes in the feedstock material from which retainer ring 48, tooth plate 28 or guide plate 24 are stamped or otherwise formed, can result in clearance 60 being too small, leading to failure of disc recliner device 20, or too large, leading to BSR noise.
[0030] Accordingly, in the method of the present invention, a set of upper dies 120 is fabricated, each die differing to accommodate variations in feedstock materials of device 20. In a presently preferred embodiment, a set of three upper dies 120a, 120b and 120c are fabricated as shown in Figure 7.
[0031] Upper die 120a is fabricated with the spacing 140 between first compression surface 136 and second compression surface 132 being the nominally correct spacing, determined as described above.
[0032] Upper die 120b is fabricated with the spacing 144 between first compression surface 136 and second compression surface 132 being a selected amount less than spacing 140.
[0033] Upper 120c is fabricated with the spacing 148 between first compression surface 136 and second compression surface 132 being a selected amount greater than spacing 140.
[0034] In accordance with the method of the present invention, one of the set of upper dies, such as upper die 120a, is mounted in press 100 and the components for assembling a disc recliner device 20, or other device, are then loaded into press 100 and press 100 is cycled to produce a test device 20. While only a single test device 20 need be produced, it is presently preferred to produce three or more test devices 20 to ensure that press 100 is operating under its normal operating conditions.
[0035] Each test device 20 is removed from press 100 in turn and is examined by the press operator, or other individual or system, to determine if a desired value for clearance 60 has been properly achieved.
[0036] If the desired value for clearance 60 has been achieved for the test devices 20, then production of devices 20 can proceed until a batch change occurs for any of the components of device 20 which would affect clearance 60 of devices 20.
[0037] Specifically, each relevant component of device 20 is organized in batches, each batch being formed from a single lot of feedstock material for that component. Thus, for example, if the guide plate 24 of device 20 is formed by stamping from a steel feedstock, when that lot of feedstock is exhausted, those stamped guide plates 24 constitute a batch and guide plates 24 stamped from a new lot of steel feedstock will constitute a new batch.
[0038] In the method of the present invention, one or more test devices 20 are fabricated and examined any time a batch of any of the relevant components of device 20 changes. As will be apparent to those of skill in the art, the relevant components of device 20 are those where a change of dimensional tolerances could affect the resulting dimension of clearance 60.
[0039] If, when test devices 20 are examined, it is determined that clearance 60 of the test devices 20 is too large, the upper die 120 (120a in this example) is removed from press 100 and is replaced with an upper die (120b in this example) with a reduced spacing, relative to the removed upper die 120, between first compression surface 136 and second compression surface 132.
[0040] One or more additional test devices 20 are then formed in press 100 with the replacement upper die 120 and these additional test devices 120 are then examined to determine if clearance 60 is within the desired range. If clearance 60 is acceptable, then production of devices 20 can proceed until the next occurrence of a batch change occurs for any of the relevant components of device 20.
[0041] If clearance 60 is above the desired range, then upper die 120 is removed from press 100 and is replaced with another upper die which has a reduced spacing between first compression surface 136 and second compression surface 132, relative to the removed upper die, and one or more test devices 20 are again fabricated and examined.
[0042] Alternatively, if test devices 20 are examined and it is determined that clearance 60 is below the desired range, then the upper die 120 in press 100 is removed and replaced with an upper die 120 (such as upper die 120c) with an increased spacing, relative to the removed upper die 120, between first compression surface 136 and second compression surface 132. One or more test devices 20 are then fabricated with the replacement upper die and are examined. If the test devices now have a clearance 60 within the desired range, production of devices 20 proceeds under the next batch change. Conversely, if the test devices are not staked within specification, then upper die 120 is exchanged with an appropriate alternate upper die 120, either one with increased spacing in the case of clearance 60 being below the desired range, or one with reduced spacing in the case of clearance 60 being greater than the desired range.
[0043] As will be apparent to those of skill in the art, the present invention is not limited to the use of any particular number of variant upper dies and the appropriate number of variant dies will be depend upon the expected variations in feedstock materials. In a current use of the method of the present invention, it has been found that three variant upper dies 120 are sufficient but it contemplated that in other circumstances more or fewer variants may be appropriate.
[0044] In a second embodiment of the present invention, the staking of the components of device 20 and the compression and/or deformation of surface 64 to set clearance 60 have been separated into separate manufacturing steps. In this embodiment, devices 20 are staked in a conventional staking press. Staked devices 20 are then loaded into a clearance setting press which comprises a lower rest having a complementary shape to, and supporting, the lower surface of device 20 and a ram to which a compression die is mounted. The compression die is shaped to engage and appropriately deform surface 64 when the ram is moved toward the lower rest.
[0045] To set clearance 60, the ram of the clearance setting press is moved toward a device 20 on the lower rest, bringing the compression die into contact with surface 64. A control system, such as a microcontroller, monitors the force which the ram exerts on surface 64, via the compression die, and controls the ram such that a pre-selected force is exerted on surface 64, after which the ram is retracted.
[0046] The pre-selected force can be determined in a variety of ways, including through empirical testing, and is the force which is sufficient to deform surface 64 to obtain a clearance 60 within the desired range of clearances.
[0047] In one presently preferred embodiment, the pre-selected force is selected such that surface 64 (or features on surface 64, such as dimples, etc.) is brought into contact with tooth plate 28 and clearance 60 is formed by the rebound of surface 60 as the ram and compression die are retracted.
[0048] As will be apparent to those of skill in the art, the pre-selected force and rebound of surface 64 are substantially independent of expected tolerance changes in the components of device 20 and thus in this embodiment of the present invention the manufacture of devices 20 need not be arranged in batches and the manufacturing can be performed as a continuous process.
[0049] The present invention provides a novel method for staking components in a mechanical device to achieve a resulting staked device with at least one desired inter-component clearance independent of feedstock variations in the materials used to form the components.
Variants are fabricated for at least one of the pair of stacking dies used in the staking press and the variant with an appropriate staking clearance is selected each time a batch of components changes. In this manner, variations between lots of feedstock materials used to form the components will not result in staked devices which suffer from lateral looseness or other staking results which do not meet the specifications for the device. In a second embodiment, devices are first staked in a conventional staking press and are then loaded into a clearance setting press which deforms at least a portion of the staked device to obtain the desired clearance. By carefully limiting the force with which the deformation is performed, the desired clearance can be obtained without requiring the batching of components in the manufacturing process.
[0050] The above-described embodiments of the invention are intended to be examples of the present invention and alterations and modifications may be effected thereto, by those of skill in the art, without departing from the scope of the invention which is defined solely by the claims appended hereto.
[ooos] Previous attempts to reduce undesired looseness by tighten tolerances on the feedstock materials have resulted in an unacceptable increase in manufacturing costs. Other attempts to mitigate the symptoms of the undesirable looseness, such as BSR, have included adding elastomeric materials to the staked devices but such materials also increase manufacturing costs and may have unacceptably short lifetimes within the devices.
[0006] It is desired to have a method for staking an assembly of components in a mechanical device which can avoid undesired looseness of components in the staked device.
SUMMARY OF THE INVENTION
[0007) It is an object of the present invention to provide a novel system and method for staking an assembly of components in a mechanical device which obviates or mitigates at least one disadvantage of the prior art.
[0008] According to a first aspect of the present invention, there is provided a method of method for staking an assembly of components in a mechanical device comprises the steps of:
(i) forming at least one test device using a pair of staking dies in a press;
(ii) examining the at least one test device to determine if a clearance between components in the device has been properly achieved; (iii) if the clearance has not been properly achieved, changing at least one of the pair of staking dies in the press and restarting the method at step (i);
(iv) if the clearance has been properly achieved, producing devices with the pair of staking dies; and (v) restarting the method at step (i) if a batch change occurs to any component being staked in the device wherein a dimensional change in the changed component could affect the clearance.
[00091 Preferably, step (iii) comprises determining whether the clearance of the at least one test device was too large or too small and, if too small, changing at least one of the pair of dies to increase the clearance of the dies, or, if too large, changing at least one of the pair of dies to decrease the clearance of the dies.
[0010] According to another aspect of the present invention, there is provided a method for staking an assembly of components in a mechanical device wherein the resulting devices have a pre-selected clearance between two or more components, comprising the steps of: (i) loading the components into a staking press and staking the components to form a staked device; (ii) loading the staked device into a clearance setting press comprising a support on which the device rests and a compression die attached to a ram, the compression die being operable to engage a portion of the staked device to deform the portion of the device to set the pre-selected clearance; and (iii) moving the ram to bring the compression die into contact with the portion of the device with a pre-selected force to deform the portion to set the pre-selected clearance.
[0011] The present invention provides a novel method for staking components in a mechanical device to achieve a resulting staked device with at least one desired inter-component clearance independent of feedstock variations in the materials used to form the components.
Variants are fabricated for at least one of the pair of stacking dies used in the staking press and the variant with an appropriate staking clearance is selected each time a batch of components changes. In this manner, variations between lots of feedstock materials used to form the components will not result in staked devices which suffer from lateral looseness or other staking results which do not meet the specifications for the device. In a second embodiment, devices are first staked in a conventional staking press and are then loaded into a clearance setting press which deforms at least a portion of the staked device to obtain the desired clearance. By carefully limiting the force with which the deformation is performed, the desired clearance can be obtained without requiring the batching of components in the manufacturing process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Preferred embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:
Figure 1 shows an exploded view of a disc recliner for an automotive seat back which can be manufactured in accordance with the present invention;
Figure 2 shows a partial section through a staked disc recliner of Figure 1;
Figure 3 shows a cross sectional view of a portion of a staking press in accordance with the method of the present invention with the press open and loaded with a set of components for the disc recliner of Figure 1;
Figure 4 shows a similar cross sectional view to that of Figure 3 with the press closed to stake the upper and lower components of the device together;
Figure 5 shows a side cross section of an upper die useful in the press of Figure 2;
Figure 6 shows a perspective view of the die of Figure 5; and Figure 7 shows a portion of side cross section of three upper dies which can be employed with the press of Figure 2.
DETAILED DESCRIPTION OF THE INVENTION
[0013] While the following discussion of the system and method of the present invention makes reference to the staking of a specific device, specifically a known disc recliner, as an example of a device which can be advantageously manufactured with the system and method of the present invention, the present invention is not limited to use in manufacturing this disc recliner or any other specific device. Instead, the present invention can be advantageously employed to manufacture a wide variety of devices as will occur to those of skill in the art.
[0014] As mentioned above, a known disc recliner is indicated generally at 20 in Figure 1.
Devices such as disc recliner 20 are commonly employed to provide for the positioning of an automotive seat back with respect to the set base.
[0015] As shown in the Figure, disc recliner 20 comprises a guide plate 24, which can be attached to a seat base, and a tooth piate 28 which can be attached to a seat back. A set of pawls 32 are located within guide plate 24 and are biased by a spring 36 to lock the angular position of tooth plate 28 with respect to guide plate 24 by engaging a set of teeth located about the inner peripheral lip of tooth plate 28. A shaft 40 includes a cam 44 which is located within set of pawls 32. Finally, a retainer ring 48 is staked to guide plate 24, enclosing the other components of disc recliner 20, to complete assembly of disc recliner 20.
[0016] When it is desired to alter the angular position of tooth plate 28 with respect to guide plate 24, thus altering the position of the seat back with respect to the seat base, a lever (not shown) attached to shaft 40 is moved, rotating shaft 40 and bringing the cam surfaces of cam 44 into contact with the set of pawls 32.
[0017] Cam 44 moves pawls 32 out of contact with the teeth of tooth plate 28, against the biasing force of spring 36, which allows relative angular movement between tooth plate 28 and guide plate 24.
[0018] When the seat back is positioned as desired, the lever is released and cam 44 allows set of pawls 32 to reengage the teeth of tooth plate 28 under the bias force of spring 36, thus again fixing the angular position of tooth plate 28 with respect to guide plate 24 and the seat back with respect to the seat base.
[0019] As shown in Figure 2, when retainer ring 48 is staked to guide plate 24, a clearance 60 must be provided between tooth plate 28 and the radial upper surface 64 of retainer ring 48 to allow tooth plate 28 to rotate with respect to guide plate 28 and retainer ring 48 when set of pawls 32 are disengaged from tooth plate 28.
[0020] While clearance 60 must be sufficient to allow for rotation of tooth plate 28, if clearance 60 is excessive, tooth plate 28 will be capable of excessive movement within disc recliner 20 and can thus produce undesired BSR noise. Accordingly, control of clearance 60 is important to avoid undesired BSR noise while still permitting correct operation of disc recliner 20.
[0021] As mentioned above, the present invention is not limited to the manufacture of disc recliners 20, or the like, and many other staked devices have similar issues with clearances between components and the present invention can advantageously be employed in the manufacture of such devices.
[0022] Figure 3 shows a staking press 100, used in a method in accordance with the present invention. Press 100 can be generally conventional and preferably includes a base portion 104, to which a lower die 108 is affixed, and which also preferably includes a locator 112 which assists in loading and aligning the components to be staked by press 100.
[0023] In the illustrated embodiment, disc recliner 20 being staked by press 100, but as mentioned above a variety of other devices can be staked in accordance with the present invention.
[00241 Press 100 further includes a ram 116 to which an upper die 120, an example of which is best seen in Figures 5 and 6, is mounted. Upper die 120 includes a cavity 124 with an appropriate shape and volume to receive the upper portion of disc recliner device 20 when upper die 120 is brought into contact with lower die 108 as press 100 is cycled.
(00251 In the illustrated embodiment, much like a conventional staking operation, guide plate 24 of disc recliner device 20 rests on lower die 108 with the remaining components of disc recliner 20 resting atop it. Press 100 is then closed, with retainer ring 48 being received in cavity 124 and the lower edge of retainer ring 48 engages lower die 108 which folds the lower edge over and onto the edge of the lower side of guide plate 24 to stake disc recliner device 20 together as shown in Figures 2 and 4.
[0026] However, unlike known staking presses and methods, upper die 120 further includes a first compression surface 136 and second compression surface 132 which engage the upper radial surface 64 of retainer ring 48 as press 100 is closed, such that upper radial surface 64 is compressed downward to reduce clearance 60.
(0027] Upper die 120 further includes an abutment surface 136 which abuts a corresponding abutment surface on lower die 108 to stop the closing of press 100 when upper die 120 and lower die 108 are fully closed and to thus prevent over compression of upper radial surface 64 of retainer ring 48.
[0028] First compression surface 136 and second compression surface 132 are vertically spaced in upper die 120 at a specified distance which is selected such that the deformation of upper radial surface 64 will result in a desired clearance 60. This vertical spacing is determined, as is known to those of skill in the art, by the design of upper die 120, the relative distances between first compression surface 136 and second compression surface 132, the thickness of the material from which retainer ring 48 is formed and the vertical height of the components of disc recliner device 20 loaded into press 100 for staking.
[0029] Once the correct vertical spacing has been determined and upper die 120 fabricated, changes in the thicknesses of components of disc recliner device 20, such as changes in the feedstock material from which retainer ring 48, tooth plate 28 or guide plate 24 are stamped or otherwise formed, can result in clearance 60 being too small, leading to failure of disc recliner device 20, or too large, leading to BSR noise.
[0030] Accordingly, in the method of the present invention, a set of upper dies 120 is fabricated, each die differing to accommodate variations in feedstock materials of device 20. In a presently preferred embodiment, a set of three upper dies 120a, 120b and 120c are fabricated as shown in Figure 7.
[0031] Upper die 120a is fabricated with the spacing 140 between first compression surface 136 and second compression surface 132 being the nominally correct spacing, determined as described above.
[0032] Upper die 120b is fabricated with the spacing 144 between first compression surface 136 and second compression surface 132 being a selected amount less than spacing 140.
[0033] Upper 120c is fabricated with the spacing 148 between first compression surface 136 and second compression surface 132 being a selected amount greater than spacing 140.
[0034] In accordance with the method of the present invention, one of the set of upper dies, such as upper die 120a, is mounted in press 100 and the components for assembling a disc recliner device 20, or other device, are then loaded into press 100 and press 100 is cycled to produce a test device 20. While only a single test device 20 need be produced, it is presently preferred to produce three or more test devices 20 to ensure that press 100 is operating under its normal operating conditions.
[0035] Each test device 20 is removed from press 100 in turn and is examined by the press operator, or other individual or system, to determine if a desired value for clearance 60 has been properly achieved.
[0036] If the desired value for clearance 60 has been achieved for the test devices 20, then production of devices 20 can proceed until a batch change occurs for any of the components of device 20 which would affect clearance 60 of devices 20.
[0037] Specifically, each relevant component of device 20 is organized in batches, each batch being formed from a single lot of feedstock material for that component. Thus, for example, if the guide plate 24 of device 20 is formed by stamping from a steel feedstock, when that lot of feedstock is exhausted, those stamped guide plates 24 constitute a batch and guide plates 24 stamped from a new lot of steel feedstock will constitute a new batch.
[0038] In the method of the present invention, one or more test devices 20 are fabricated and examined any time a batch of any of the relevant components of device 20 changes. As will be apparent to those of skill in the art, the relevant components of device 20 are those where a change of dimensional tolerances could affect the resulting dimension of clearance 60.
[0039] If, when test devices 20 are examined, it is determined that clearance 60 of the test devices 20 is too large, the upper die 120 (120a in this example) is removed from press 100 and is replaced with an upper die (120b in this example) with a reduced spacing, relative to the removed upper die 120, between first compression surface 136 and second compression surface 132.
[0040] One or more additional test devices 20 are then formed in press 100 with the replacement upper die 120 and these additional test devices 120 are then examined to determine if clearance 60 is within the desired range. If clearance 60 is acceptable, then production of devices 20 can proceed until the next occurrence of a batch change occurs for any of the relevant components of device 20.
[0041] If clearance 60 is above the desired range, then upper die 120 is removed from press 100 and is replaced with another upper die which has a reduced spacing between first compression surface 136 and second compression surface 132, relative to the removed upper die, and one or more test devices 20 are again fabricated and examined.
[0042] Alternatively, if test devices 20 are examined and it is determined that clearance 60 is below the desired range, then the upper die 120 in press 100 is removed and replaced with an upper die 120 (such as upper die 120c) with an increased spacing, relative to the removed upper die 120, between first compression surface 136 and second compression surface 132. One or more test devices 20 are then fabricated with the replacement upper die and are examined. If the test devices now have a clearance 60 within the desired range, production of devices 20 proceeds under the next batch change. Conversely, if the test devices are not staked within specification, then upper die 120 is exchanged with an appropriate alternate upper die 120, either one with increased spacing in the case of clearance 60 being below the desired range, or one with reduced spacing in the case of clearance 60 being greater than the desired range.
[0043] As will be apparent to those of skill in the art, the present invention is not limited to the use of any particular number of variant upper dies and the appropriate number of variant dies will be depend upon the expected variations in feedstock materials. In a current use of the method of the present invention, it has been found that three variant upper dies 120 are sufficient but it contemplated that in other circumstances more or fewer variants may be appropriate.
[0044] In a second embodiment of the present invention, the staking of the components of device 20 and the compression and/or deformation of surface 64 to set clearance 60 have been separated into separate manufacturing steps. In this embodiment, devices 20 are staked in a conventional staking press. Staked devices 20 are then loaded into a clearance setting press which comprises a lower rest having a complementary shape to, and supporting, the lower surface of device 20 and a ram to which a compression die is mounted. The compression die is shaped to engage and appropriately deform surface 64 when the ram is moved toward the lower rest.
[0045] To set clearance 60, the ram of the clearance setting press is moved toward a device 20 on the lower rest, bringing the compression die into contact with surface 64. A control system, such as a microcontroller, monitors the force which the ram exerts on surface 64, via the compression die, and controls the ram such that a pre-selected force is exerted on surface 64, after which the ram is retracted.
[0046] The pre-selected force can be determined in a variety of ways, including through empirical testing, and is the force which is sufficient to deform surface 64 to obtain a clearance 60 within the desired range of clearances.
[0047] In one presently preferred embodiment, the pre-selected force is selected such that surface 64 (or features on surface 64, such as dimples, etc.) is brought into contact with tooth plate 28 and clearance 60 is formed by the rebound of surface 60 as the ram and compression die are retracted.
[0048] As will be apparent to those of skill in the art, the pre-selected force and rebound of surface 64 are substantially independent of expected tolerance changes in the components of device 20 and thus in this embodiment of the present invention the manufacture of devices 20 need not be arranged in batches and the manufacturing can be performed as a continuous process.
[0049] The present invention provides a novel method for staking components in a mechanical device to achieve a resulting staked device with at least one desired inter-component clearance independent of feedstock variations in the materials used to form the components.
Variants are fabricated for at least one of the pair of stacking dies used in the staking press and the variant with an appropriate staking clearance is selected each time a batch of components changes. In this manner, variations between lots of feedstock materials used to form the components will not result in staked devices which suffer from lateral looseness or other staking results which do not meet the specifications for the device. In a second embodiment, devices are first staked in a conventional staking press and are then loaded into a clearance setting press which deforms at least a portion of the staked device to obtain the desired clearance. By carefully limiting the force with which the deformation is performed, the desired clearance can be obtained without requiring the batching of components in the manufacturing process.
[0050] The above-described embodiments of the invention are intended to be examples of the present invention and alterations and modifications may be effected thereto, by those of skill in the art, without departing from the scope of the invention which is defined solely by the claims appended hereto.
Claims (3)
1. A method for staking an assembly of components in a mechanical device comprises the steps of:
(i) forming at least one test device using a pair of staking dies in a press;
(ii) examining the at least one test device to determine if a clearance between components in the device has been properly achieved;
(iii) if the clearance has not been properly achieved, changing at least one of the pair of staking dies in the press and restarting the method at step (i);
(iv) if the clearance has been properly achieved, producing devices with the pair of staking dies; and (v) restarting the method at step (i) if a batch change occurs to any component being staked in the device wherein a dimensional change in the changed component could affect the clearance.
(i) forming at least one test device using a pair of staking dies in a press;
(ii) examining the at least one test device to determine if a clearance between components in the device has been properly achieved;
(iii) if the clearance has not been properly achieved, changing at least one of the pair of staking dies in the press and restarting the method at step (i);
(iv) if the clearance has been properly achieved, producing devices with the pair of staking dies; and (v) restarting the method at step (i) if a batch change occurs to any component being staked in the device wherein a dimensional change in the changed component could affect the clearance.
2. The method of claim 1 wherein step (iii) comprises determining whether the clearance of the at least one test device was too large or too small and, if too small, changing at least one of the pair of dies to increase the clearance of the dies, or, if too large, changing at least one of the pair of dies to decrease the clearance of the dies.
3. A method for staking an assembly of components in a mechanical device wherein the resulting devices have a pre-selected clearance between two or more components, comprising the steps of:
(i) loading the components into a staking press and staking the components to form a staked device;
(ii) loading the staked device into a clearance setting press comprising a support on which the device rests and a compression die attached to a ram, the compression die being operable to engage a portion of the staked device to deform the portion of the device to set the pre-selected clearance; and (iii) moving the ram to bring the compression die into contact with the portion of the device with a pre-selected force to deform the portion to set the pre-selected clearance.
(i) loading the components into a staking press and staking the components to form a staked device;
(ii) loading the staked device into a clearance setting press comprising a support on which the device rests and a compression die attached to a ram, the compression die being operable to engage a portion of the staked device to deform the portion of the device to set the pre-selected clearance; and (iii) moving the ram to bring the compression die into contact with the portion of the device with a pre-selected force to deform the portion to set the pre-selected clearance.
Priority Applications (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2598137 CA2598137C (en) | 2007-08-20 | 2007-08-20 | System and method for staking an assembly of components with compensation for component tolerances |
| CN2008101458793A CN101372026B (en) | 2007-08-20 | 2008-08-18 | System and method for staking an assembly of components withcompensation for component tolerances |
| KR1020080080806A KR101429775B1 (en) | 2007-08-20 | 2008-08-19 | System and method for staking component assembly using compensation for component tolerance |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2598137 CA2598137C (en) | 2007-08-20 | 2007-08-20 | System and method for staking an assembly of components with compensation for component tolerances |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2598137A1 CA2598137A1 (en) | 2009-02-20 |
| CA2598137C true CA2598137C (en) | 2015-04-28 |
Family
ID=40374847
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2598137 Active CA2598137C (en) | 2007-08-20 | 2007-08-20 | System and method for staking an assembly of components with compensation for component tolerances |
Country Status (3)
| Country | Link |
|---|---|
| KR (1) | KR101429775B1 (en) |
| CN (1) | CN101372026B (en) |
| CA (1) | CA2598137C (en) |
Family Cites Families (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB382135A (en) * | 1931-01-13 | 1932-10-20 | Manganese Bronze And Brass Com | Apparatus for sizing or burnishing tubular metal elements |
| KR950005523Y1 (en) * | 1990-10-18 | 1995-07-13 | 대우전자 주식회사 | Plunger Staking Device for Solenoid Valves for IC Fan Heaters |
| JP4099760B2 (en) * | 2002-12-25 | 2008-06-11 | アイシン精機株式会社 | Vehicle seat device |
| PL1620049T3 (en) * | 2003-05-02 | 2007-06-29 | Albert Daxer | Device for cutting the cornea of an eye |
| CA2575121C (en) * | 2004-08-03 | 2013-07-09 | Intier Automotive Inc. | Extended travel rotating mechanism |
| CN101243260A (en) * | 2005-07-11 | 2008-08-13 | 盖茨公司 | Tolerance compensating connector |
| DE202006012493U1 (en) | 2006-08-14 | 2006-11-02 | Böllhoff Verbindungstechnik GmbH | Fastening device for fastening of one component to another with tolerance compensation has adjusting unit consisting of threaded sleeve and locating plate, wherein threaded sleeve is screwed into adjusting threaded nut of base unit |
| KR101105041B1 (en) * | 2009-10-13 | 2012-01-16 | 현대위아 주식회사 | Pressurizing device for gap measurement of synchroring and clutch gear |
-
2007
- 2007-08-20 CA CA 2598137 patent/CA2598137C/en active Active
-
2008
- 2008-08-18 CN CN2008101458793A patent/CN101372026B/en active Active
- 2008-08-19 KR KR1020080080806A patent/KR101429775B1/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CA2598137A1 (en) | 2009-02-20 |
| CN101372026A (en) | 2009-02-25 |
| KR101429775B1 (en) | 2014-08-18 |
| KR20090019710A (en) | 2009-02-25 |
| CN101372026B (en) | 2011-12-28 |
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