U.S. patent application number 10/124084 was filed with the patent office on 2002-10-24 for method and apparatus for manufacturing hinges.
Invention is credited to Ruddy, Steve A., Ward, Hal.
Application Number | 20020152596 10/124084 |
Document ID | / |
Family ID | 26822188 |
Filed Date | 2002-10-24 |
United States Patent
Application |
20020152596 |
Kind Code |
A1 |
Ruddy, Steve A. ; et
al. |
October 24, 2002 |
Method and apparatus for manufacturing hinges
Abstract
The instant invention is a method and apparatus for assembling
two hinge leaves. The apparatus includes an assembly for feeding a
predetermined length of a wire pintle into a shear assembly. The
shear assembly cuts the wire pintle to a specified length and
locates the wire in a channel. Substantially simultaneously with
the shearing of the wire, a punch and die assembly adjacent the
shear assembly locates the two leaves of the hinge such that the
barrels of the hinge are aligned. Once in position, a linear
actuator drives the sheared length of wire pintle into the aligned
hinge barrels to couple the two hinge leaves together. Once the
pintle has been inserted, staking pins within the punch and die
assembly impact select ones of the hinge barrels to keep the pintle
in place. Also, disclosed is a novel method of manufacturing the
two hinge leaves.
Inventors: |
Ruddy, Steve A.; (Eagle,
MI) ; Ward, Hal; (Dewitt, MI) |
Correspondence
Address: |
MILLER JOHNSON SNELL CUMMISKEY, PLC
800 CALDER PLAZA BUILDING
250 MONROE AVE N W
GRAND RAPIDS
MI
49503-2250
US
|
Family ID: |
26822188 |
Appl. No.: |
10/124084 |
Filed: |
April 17, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60284752 |
Apr 18, 2001 |
|
|
|
Current U.S.
Class: |
29/11 |
Current CPC
Class: |
Y10T 29/24 20150115;
B21D 53/40 20130101; B21K 13/02 20130101 |
Class at
Publication: |
29/11 |
International
Class: |
B21K 013/02; B21D
053/40 |
Claims
We claim as our invention:
1. An apparatus for assembling interconnecting two leaves of a
hinge by automatically inserting and clamping a pin in the barrels
of at least two leaves, the combination comprising: a first
assembly for holding the two hinge leaves together such that the
barrels of the two hinge leaves are aligned; a feed assembly for
providing a predetermined length of wire for use as a pintle; and a
second assembly for receiving said predetermined length of wire
from said feed assembly and driving said predetermined length of
wire into the aligned barrels of the two hinge leaves.
2. The apparatus as defined in claim 1, wherein said first assembly
includes: a frame assembly; a press attached to said frame
assembly; and a punch and die assembly disposed beneath said press
for receiving the two leaves of the hinge.
3. The apparatus as defined in claim 1, wherein said feed assembly
includes: a drive assembly for supplying a predetermined length of
wire to said second assembly for use as a pintle; and a wire
conditioner assembly for straightening said predetermined length of
wire.
4. The apparatus as defined in claim 1, wherein said feed assembly
includes a magazine containing at least one predetermined length of
wire to be used as a pintle to be dispensed to said second
assembly.
5. The apparatus as defined in claim 1, wherein said second
assembly, includes: a frame assembly; a press attached to said
frame assembly; and a shear assembly adjacent and acted upon by
said press for receiving said predetermined length of wire and
shearing said predetermined length of wire into a pintle.
6. The apparatus as defined in claim 2, wherein said punch and die
assembly, includes: a seat for receiving the two leaves of the
hinge in a predetermined configuration; a punch assembly having a
housing and a staking tool for engaging the two leaves of the hinge
on said seat and compressing predetermined portions of a hinge leaf
about said pintle; and an assembly for ejecting the two hinge
leaves from the seat.
7. A method for assembling two leaves of a hinge comprising the
steps of: locating and retaining within a first press assembly two
leaves of a hinge in a predetermined configuration on a seat such
that the barrels of the two hinge leaves are aligned; feeding a
predetermined length of wire for use as a pintle to a second press
assembly; and receiving said predetermined length of wire from said
feed assembly and said second press assembly, and driving said
predetermined length of wire into the aligned barrels of the two
hinge leaves using a third press assembly.
8. The method as defined in claim 7, wherein the locating step
further includes the steps of: providing a frame assembly for
supporting a linear actuator in said first press assembly; and
locating the two leaves of the hinge in a punch and die assembly
disposed beneath said linear actuator for receiving the two leaves
of the hinge.
9. The method as defined in claim 7, wherein the feeding step
includes: drawing a predetermined length of wire from a spool of
wire and supplying said predetermined length of wire to said second
assembly; and conditioning said predetermined length of wire into a
substantially straight configuration by removing any curvature in
said length of wire.
10. The method as defined in claim 7, wherein the feeding step
includes providing a magazine containing at least one predetermined
length of pintle to be dispensed to said third assembly.
11. The method as defined in claim 7, wherein said feeding step
further includes: supplying said predetermined length of wire to a
shear assembly; shearing off said predetermined length of wire to
form a pintle; and driving said pintle into the aligned barrels of
the two hinge leaves.
12. The method as defined in claim 8, wherein the step of locating
the two leaves of the hinge in a punch and die assembly, includes:
positioning the two leaves of the hinge in a predetermined
configuration on a seat; urging a housing against the two leaves of
the hinge on the seat while driving said predetermined length of
wire into the aligned barrels of the two hinge leaves by said third
press assembly; and staking predetermined portions of at least one
of said two hinge leaves about said predetermined length of
wire.
13. A method for forming a hinge assembly, comprising the steps of:
punching a first and second hinge leaves from a piece of stock,
each of said hinge leaves having knuckles substantially formed
thereon configured to mate with like knuckles on the opposite
leave; placing said first and second hinge leaves in a
predetermined configuration on a seat; compressing said first and
second hinge leaves on said seat between a punch and die such that
the knuckles are aligned; ramming a pintle into the aligned
knuckles of said first and second hinge leaves when compressed
between said punch and die; and staking predetermined ones of said
knuckles so as to positively fix said pintle therein.
14. The method as defined in claim 13, further comprising the steps
of: drawing a length of wire from a spool of wire; conditioning
said length of wire to remove any curl or bends; feeding said
length of wire into a measuring station to define a predetermined
length of wire; shearing said predetermined length of wire to form
said pintle; and aligning said pintle axially with the knuckles
prior to the step of ramming.
15. The method as defined in claim 13, further comprising the steps
of: preforming a plurality of pintles; loading said plurality of
pintles into a magazine; placing said magazine into a receiver; and
dispensing one of said plurality of pintles into a position axially
aligned with the knuckles prior to the step of ramming.
16. An apparatus for assembling knuckled hinge leaves, comprising:
a seat configured to receive a first and second hinge leaves in a
predetermined configuration such that the knuckles of each hinge
leave are aligned; a punch and die on opposite sides of said seat
for placing said first and second hinge leaves in a predetermined
and fixed orientation; a first ram adjacent said punch and die for
ramming a pintle into the aligned knuckles of said first and second
hinge leaves when in said predetermined and fixed orientation; and
a second ram adjacent said seat for staking predetermined ones of
said knuckles so as to positively fix said pintle therein.
17. The apparatus as defined in claim 16, further comprising: an
assembly for drawing a length of wire from a spool of wire; an
assembly for conditioning said length of wire to remove any curl or
bends; an assembly for feeding said length of wire into a measuring
station to define a predetermined length of wire; an assembly for
shearing said predetermined length of wire to form said pintle; an
assembly for aligning said pintle axially with the knuckles and
with said first ram.
18. The apparatus as defined in claim 16, further comprising: a
magazine for retaining a plurality of pre-formed pintles; a
receiver adjacent said first ram for holding said magazine; and a
dispensing member for depositing one of said plurality of pintles
into a position axially aligned with the knuckles and with said
first ram.
Description
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is related to provisional patent
application serial No. 60/284,752, filed on Apr. 18, 2001, the
contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to a method and apparatus
for assembling components, and more particularly to a method and
apparatus for manufacturing and assembling hinges.
[0004] 2. Description of the Related Art
[0005] Traditionally, hinges were made individually. Each leaf of
the hinge was either hand-cut or stamped from a metal black and
each of the individual hinge knuckles were rounded over a
pre-positioned pintle by hammer or one or more press operations.
Later, with mass production, the hinge leaves were stamped from a
metal blank in a series of punch and die presses. Numerous such
methods contemplated placing a pintle along the tabs which were
progressively rounded around the pintle. To expedite the process,
others formed used a continuous forming process where two hinge
leaves were formed with the knuckles formed around a continuous
length of wire pintle. At predetermined intervals, the hinges were
stamped from the continuous hinge to form the desired length.
[0006] The problem most often associated with the continuous
forming method is that subsequent steps formed on the hinge leaves
often had an impact on other dimensions of the hinge. For example,
some steps contemplate punching the fastener holes after the pintle
has been placed. The punching steps often times deforms the plates
with some extension to the knuckles or barrels. Such deformation
results in the hinge not swinging smoothly. Others cut the hinge to
length also after the pintle has been trapped. This shearing method
of the entire hinge assembly also introduces similar contortions
and deformations in the assembly, also resulting in poor operation.
Moreover, the continuous operations are problematic when an
operation problem occurs, or tools are changed. What results is a
shut down of the entire hinge manufacturing process until the fix
is corrected or the tools are changed. Moreover, there is
substantial waste in time and material associated with such
breakdowns or changes.
[0007] There has been a long felt and unfilled need to provide a
much more efficient and cost-effective way of manufacturing hinges
with fewer defects and at a cost competitive with mass production
systems. The instant invention solves those needs.
SUMMARY OF THE INVENTION
[0008] The instant invention is a method and apparatus for
assembling two hinge leaves. The apparatus includes an assembly for
feeding a predetermined length of a wire pintle into a shear
assembly. In one embodiment, a shear assembly cuts the wire pintle
to a specified length and locates the wire in a channel. In a
second embodiment, a magazine supplies pre-manufactured pintles. In
both embodiments, a punch and die assembly adjacent the feed
assembly locates the two leaves of the hinge such that the barrels
are aligned. Once in position, a linear actuator drives the wire
pintle into the aligned hinge barrels to couple the two hinge
leaves together. Once the pintle has been inserted, staking pins
within the punch and die assembly impact select ones of the hinge
barrels to keep the pintle in place. Also, disclosed is a novel
method of manufacturing the two hinge leaves.
[0009] According to one aspect of the invention, an apparatus is
provided for interconnecting two leaves of a hinge by automatically
inserting and clamping a pin in the barrels of at least two leaves,
comprising in combination a first assembly for holding the two
hinge leaves together such that the barrels of the two hinge leaves
are aligned; a feed assembly for providing a predetermined length
of wire for use as a pintle; and a second assembly for receiving
the length of wire from the feed assembly and driving the length of
wire into the aligned barrels of the two hinge leaves.
[0010] In a further form of the invention, the first assembly
includes a frame assembly; a press attached to the frame assembly;
and a punch and die assembly disposed beneath the press for
receiving the two leaves of the hinge. The feed assembly may
include a drive assembly for supplying the length of wire to the
second assembly for use as a pintle; and a wire conditioner
assembly for straightening the length of wire. The feed assembly
alternatively may include a magazine containing at least one length
of wire to be used as a pintle to be dispensed to the second
assembly. The second assembly may include a frame assembly; a press
attached to the frame assembly; and a shear assembly adjacent and
acted upon by the press for receiving the length of wire and
shearing the length of wire into the pintle. The punch and die
assembly briefly mentioned above may include a seat for receiving
the two leaves of the hinge in a predetermined configuration; a
punch assembly having a housing and a staking tool for engaging the
two leaves of the hinge on the seat and compressing predetermined
portions of a hinge leaf knuckle about the pintle; and an assembly
for ejecting the interconnected hinge leaves from the seat.
[0011] The invention also includes a method for assembling the two
leaves of a hinge including the steps of locating and retaining
within a first press assembly two leaves of a hinge in a
predetermined configuration on a seat such that the barrels of the
two hinge leaves are aligned; feeding a length of wire for use as a
pintle to a second press assembly; and receiving the length of wire
from the feed assembly and the second press assembly, and driving
the length of wire into the aligned barrels of the two hinge leaves
using a third press assembly. The locating step may further include
the steps of providing a frame assembly for supporting a linear
actuator in the first press assembly; and locating the two leaves
of the hinge in a punch and die assembly disposed beneath the
linear actuator for receiving the two leaves of the hinge. The
feeding step may include drawing a predetermined length of wire
from a spool of wire and supplying that length of wire to the
second assembly; and conditioning the length of wire into a
substantially straight configuration by removing any curvature.
Alternatively, the feeding step may include providing a magazine
containing at least one predetermined length of pintle to be
dispensed to the third assembly. The feeding step may farther
include supplying the length of wire to a shear assembly; shearing
the length of wire to form a pintle; and driving the pintle into
the aligned barrels of the two hinge leaves. Moreover, the step of
locating the two leaves of the hinge in a punch and die assembly
may include positioning the two leaves of the hinge in a
predetermined configuration on a seat; urging a housing against the
two leaves of the hinge on the seat while driving the length of
wire into the aligned barrels of the two hinge leaves by the third
press assembly; and staking predetermined portions of at least one
of the hinge barrels about the predetermined length of wire to hold
it in the hinge.
[0012] According to another form of the invention a method is
provided for forming a hinge assembly, and includes the steps of
punching a first and second hinge leaves from a piece of stock,
each of said hinge leaves having knuckles substantially formed
thereon and configured to mate with like knuckles on the opposite
leaf. Placing the first and second hinge leaves in a predetermined
configuration on a seat and compressing the first and second hinge
leaves on the seat between a punch and die such that the knuckles
are aligned. Once aligned, ramming a pintle into the knuckles of
the first and second hinge leaves when compressed between said
punch and die. Finally, staking predetermined ones of the knuckles
so as to positively fix the pintle therein. The method may further
include the steps of drawing a length of wire from a spool of wire
and conditioning the length of wire to remove any curl or bends.
Following conditioning, feeding the length of wire into a measuring
station to define a predetermined length of wire. From there,
shearing the predetermined length of wire to form the pintle.
Finally, aligning the pintle axially with the knuckles prior to the
step of ramming. The method may further include preforming a
plurality of pintles, loading the plurality of pintles into a
magazine, placing the magazine into a receiver, and dispensing one
of the plurality of pintles into a position axially aligned with
the knuckles prior to the step of ramming.
[0013] In another form of the invention, a seat is configured to
receive a first and second hinge leaves in a predetermined
configuration such that the knuckles of each hinge leave are
aligned. A punch and die exists on opposite sides of the seat for
placing the first and second hinge leaves in a predetermined and
fixed orientation. A first ram is located adjacent the punch and
die for ramming a pintle into the aligned knuckles of the first and
second hinge leaves when placed in that predetermined and fixed
orientation. A second ram lies adjacent the seat for staking
predetermined ones of the hinge knuckles so as to positively fix
the pintle therein. The invention further includes an assembly for
drawing a length of wire from a spool of wire, an assembly for
conditioning the length of wire to remove any curl or bends, an
assembly for feeding the length of wire into a measuring station to
define a pintle length, an assembly for shearing the length to form
the pintle, and an assembly for aligning the pintle axially within
the knuckles. The invention may also include a magazine for
retaining a plurality of preformed pintles. The magazine fits into
a receiver which adjacent the first. The magazine also includes a
dispensing member for depositing one of the plurality of pintles
into a position axially aligned with the knuckles and with said
first ram.
[0014] A better understanding of the invention will be attained by
reference to the following drawing figures as well as the
subsequent detailed written description of the different
embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0015] FIG. 1 is a schematic side elevation of one embodiment of
the invention;
[0016] FIG. 2 is a schematic plan view of the invention shown in
FIG. 1;
[0017] FIG. 3 is an end elevation of the invention shown in FIG.
1;
[0018] FIG. 4 is an end view of the intermediate press assembly
shown in FIG. 1;
[0019] FIG. 5 is a bottom plan view of the punch assembly shown in
FIG. 3;
[0020] FIG. 6 is a plan view of the die assembly shown in FIG.
3;
[0021] FIG. 7 is an enlarged side elevation view of the shear
assembly shown in FIGS. 1, 2, and 4;
[0022] FIG. 8 is an enlarged end section view of the shear assembly
shown in FIG. 7;
[0023] FIG. 9 is a schematic side elevation of another embodiment
of the invention;
[0024] FIG. 10 is a schematic plan view of the invention shown in
FIG. 9;
[0025] FIG. 11 is an end elevation of the invention shown in FIG.
9; and
[0026] FIG. 12 is an end elevation of one embodiment of a drive
mechanism for a portion of the invention shown in FIG. 9.
DESCRIPTION OF ONE EMBODIMENT OF THE INVENTION
[0027] For purposes of the following description, the terms
"upper," "lower," "left," "rear," "front," "vertical," "horizontal"
and derivatives of such terms shall relate to the invention as
oriented in drawing FIG. 2. However, it is to be understood that
the invention may assume various alternative orientations, except
where expressly specified to the contrary. It is also to be
understood that the specific devices and processes illustrated in
the attached drawings, and described in the following specification
are simply exemplary embodiments of the inventive concepts defined
in the appended claims. Specific dimensions and other physical
characteristics relating to the embodiments disclosed herein are
not to be considered as limiting, unless the claims expressly state
otherwise. However, it is to be understood that the dimensions of
the various components may be changed or altered in order to
satisfy different requirements and components.
[0028] Referring generally to the attached drawing figures, an
apparatus is provided for interconnecting two leaves of a hinge by
automatically inserting and clamping a pin in the barrels of at
least two leaves, comprising in combination a first assembly for
holding the two hinge leaves together such that the barrels of the
two hinge leaves are aligned; a feed assembly for providing a
predetermined length of wire for use as a pintle; and a second
assembly for receiving the length of wire from the feed assembly
and driving the length of wire into the aligned barrels of the two
hinge leaves. The first assembly may include a frame assembly; a
press attached to the frame assembly; and a punch and die assembly
disposed beneath the press for receiving the two leaves of the
hinge. The feed assembly may include a drive assembly for supplying
the length of wire to the second assembly for use as a pintle; and
a wire conditioner assembly for straightening the length of wire.
The feed assembly alternatively may include a magazine containing
at least one length of wire to be used as a pintle to be dispensed
to the second assembly. The second assembly may include a frame
assembly; a press attached to the frame assembly; and a shear
assembly adjacent and acted upon by the press for receiving the
length of wire and shearing the length of wire into the pintle. The
punch and die assembly briefly mentioned above may include a seat
for receiving the two leaves of the hinge in a predetermined
configuration; a punch assembly having a housing and a staking tool
for engaging the two leaves of the hinge on the seat and
compressing predetermined portions of a hinge leaf knuckle about
the pintle; and an assembly for ejecting the interconnected hinge
leaves from the seat.
[0029] In another form of the invention, a seat is configured to
receive a first and second hinge leaves in a predetermined
configuration such that the knuckles of each hinge leave are
aligned. A punch and die exists on opposite sides of the seat for
placing the first and second hinge leaves in a predetermined and
fixed orientation. A first ram is located adjacent the punch and
die for ramming a pintle into the aligned knuckles of the first and
second hinge leaves when placed in that predetermined and fixed
orientation. A second ram lies adjacent the seat for staking
predetermined ones of the hinge knuckles so as to positively fix
the pintle therein. The invention further includes an assembly for
drawing a length of wire from a spool of wire, an assembly for
conditioning the length of wire to remove any curl or bends, an
assembly for feeding the length of wire into a measuring station to
define a pintle length, an assembly for shearing the length to form
the pintle, and an assembly for aligning the pintle axially within
the knuckles. The invention may also include a magazine for
retaining a plurality of pre-formed pintles. The magazine fits into
a receiver which adjacent the first. The magazine also includes a
dispensing member for depositing one of the plurality of pintles
into a position axially aligned with the knuckles and with said
first ram.
[0030] In one embodiment of the instant invention, a punch and die
assembly may be disposed at one end of a progressive die assembly
used to manufacture hinge leaves from a continuous sheet of
material. Disposed at one end of the progressive die assembly is a
spool containing a band of steel, aluminum, or plastic which passes
through the various punch and die sets contained within the
progressive die. Details on the progressive die assembly will not
be provided in this description. However, the steps of the
progressive die assembly in the manufacturing of the hinge
described in greater detail below are considered to be novel,
particularly when used in combination with the instant invention.
Although a progressive die assembly is mentioned as carrying out
the method of forming the hinge components, it is contemplated the
manufacture of those same components may be carried out by hand or
with separate machines to achieve the same result. However, one of
the substantial benefits of the progressive die assembly is the
faster, and substantially automated production of work pieces than
should the steps be done separately.
[0031] Referring now specifically to drawing FIGS. 1-6, a punch and
die assembly 20 includes a first press assembly 30 at one end, a
second or intermediate press assembly 32, and a feed assembly 34
disposed at an opposite end. All three assemblies (30, 32, and 34)
are preferably mounted to a work surface or table 36 disposed at a
predetermined height above a reference plane such as the floor. The
table 36 is preferably designed so as to receive one or more bins
38 positioned to receive finished work pieces. In one embodiment,
bin 38 is shown disposed beneath the upper surface of the table 36
to receive finished work pieces through a hole in the work surface.
However, the location of the receiving bin 38 may be adjacent
assembly 20 as well.
[0032] In one embodiment of the invention, it is contemplated the
first press assembly 30 (FIGS. 1 and 3) completes the final
assembly process. Assembly 30 may include a frame assembly 40
formed from at least one, and preferably two uprights 42, 44 spaced
from each other, each having a lower edge attached to the upper
surface of the table 36. Each upright 42, 44 may also have a
centralized opening 46. In the embodiment shown, the two uprights
42, 44 support a linear actuator 48 having a downwardly directed
piston 50. The lower end of the actuator 48 may be retained by a
collar 52 or other structure which is attached to the upper edge of
the centralized opening in each upright 42, 44. It is contemplated
that the linear actuator may be a conventional hydraulicly-driven
actuator, although it is preferred an air-driven oil system be
used.
[0033] Also mounted to the uprights 42,44 at a lower edge of the
centralized opening 46, is a punch and die assembly generally
designated by the numeral 54, the principal components of which are
shown in greater detail in drawing FIGS. 5 and 6. In general, punch
and die assembly 54 may include an upper platen 56 supported above
a lower platen 58 by a plurality of telescoping and biased guides,
columns or posts 60 intended to keep the two platens 56, 58 in
registered alignment as one is moved toward the other. In this
embodiment of the invention, it is designed such that the upper
platen 56 moves relative to the lower platen 58 under the force of
piston 50.
[0034] Mounted on the upper surface of the lower platen 58 may be a
cradle or seat 62 which is configured to receive the mating halves
or leaves of the hinge assembly described in greater detail below.
Because the overall design of the invention is designed to function
in a generally vertical plane, seat 62 is oriented substantially
horizontally such that when the two hinge leaves are placed on the
seat, the barrels of the two halves are received in registered
alignment in the valley or bottom-most portion of the seat. The
seat 62 preferably includes two or more optical or magnetic
proximity sensors (not shown) which can be used to detect the
placement and proper orientation of the two mating hinge leaves.
Moreover, for that matter, optical or magnetic proximity sensors
are preferably used at multiple locations throughout the invention
to provide the position and/or status of the various components. It
is anticipated that seat 62 may also be designed to be
polarized--that is, receive the two hinge leaves only in a single
configuration. Additionally, the coupling arrangement of the seat
62 to the lower platen 58 permits seats 62 of different dimensions
to be used.
[0035] Attached to the upper platen 56 is a punch assembly 64
including a housing 66 for retaining a positioning press assembly
68. The positioning press assembly 68, in turn, includes a staking
tool described in greater detail below. With the two leaves of the
hinge assembly properly in position in the seat 62, the positioning
press assembly 68 is lowered such that contours on the lower edge
of the staking tool ensure the barrels of the two hinge leaves are
aligned and facilitate the final staking of the leaves in the
assembly.
[0036] Adjacent the first press assembly 30 is the second press
assembly 32. The purpose of the second press assembly is to cut or
shear a strand of wire to a predetermined length, and then drive
the wire into the aligned barrels of the two hinge leaves. As best
illustrated in the embodiment illustrated by drawing FIGS. 1, 2 and
4, the second press assembly may include its own frame assembly 70
formed by at least one, and preferably two uprights 72, 74 attached
at their lower ends to the upper surface of the table 36.
Interconnecting the upper ends of the uprights 72, 74 may be a
cross member 76 (FIGS. 1 and 4) which in turn may be attached to a
collar 78 supporting the lower end of a second linear actuator 80.
Just as with linear actuator 48, actuator 80 includes a downwardly
oriented piston 82.
[0037] Disposed beneath piston 82, and supported by the lower
portion of uprights 72, 74 is shear assembly 84. Referring to FIGS.
7 and 8, the shear assembly 84 includes a V-shaped channel guide 86
centrally disposed within the shear assembly 84 and has one end 88
adjacent to and aligned with the cradle or seat 62. Moreover, the
shear assembly 84 is mounted on the lower platen 58 in order to
maintain the alignment and close proximity of the seat 62 with
assembly 84. The channel guide 86 is preferably disposed directly
beneath a biased shear plate 90 disposed in the upper end of shear
assembly 84. The shear plate 90 may also be located just slightly
above a horizontally disposed passage or port 92 through which the
wire stock for the hinge pin (also known as a pintle) is received.
Opposite port 92 is a gauge assembly 94 having an adjustable pin 96
provided to establish the length of the pintle to be sheared by
plate 90. As the shear plate 90 is depressed by piston 82 to shear
the pin extending beyond passage 92, the pin falls into the
V-shaped channel guide 86.
[0038] Disposed at one end 98 of shear assembly 84 is a
horizontally disposed actuator assembly 100. Actuator assembly 100
includes a carriage 102 attached to the end of a piston 104 which
is provided to drive the pintle along the V-shaped channel guide 86
and into the aligned barrels of the hinge leaves. As illustrated in
FIG. 4, the V-shaped channel guide 86 includes a longitudinal
channel or slot 106 located at the bottom through which the
carriage 102 passes, driven by the piston 104 located in a passage
107 disposed beneath the V-shaped channel guide assembly 86. The
longitudinal slot 106 ensures that the carriage 102 is aligned with
the guide pin and properly driven into the aligned barrels of the
hinge assembly.
[0039] One embodiment of the feed assembly 34 is best illustrated
in FIGS. 1 and 2. Feed assembly 34 may include a drive assembly 110
and a wire conditioning assembly 112. The drive assembly 110
preferably includes a motor 114 attached to a gear box or
transmission 116, both of which are interconnected to an upright
118 by a mounting bracket 120. The upright 118, in turn, is coupled
to the work surface or table 36 by a bottom plate 122 and bulkhead
124. Extending below the transmision 116 is a drive 126 having
drive wheels 128 and 130 disposed on opposite sides of the incoming
wire and configured to frictionally engage the wire so as to cause
it to feed into shear assembly 84. In the drawing figures, two
drive wheels 128, 130 are illustrated to advance the wire. However,
it should be understood that alternate drive methods may also be
used including a linearly moving rachet-type system or
counter-rotating belt or track drive system which engages a
substantially greater length of the incoming wire. No matter what
drive system is elected, it should be further understood that the
material provides a frictional engagement with the incoming wire in
order to maximize the advance of the wire into the shear assembly
84.
[0040] Adjacent the drive assembly and located proximate the
opposite end of the table 36 from the first press assembly 30 is
the wire conditioning assembly 112. The purpose of the wire
conditioning assembly is to straighten the wire prior to being feed
in the shear assembly described above. The wire conditioning
assembly 112 may include a base plate 134 for supporting an upright
136 bolstered by a bulkhead 138. Mounted to the upper end of the
upright 136 may be a lower and upper jaw 140, 142 respectively. The
lower jaw 140 may be attached to the upright 136 while the upper
jaw 142 may be interconnected in registered alignment with the
lower jaw 140 and spring biased such that the upper jaw is in a
naturally open position with respect to the lower jaw 140. In the
preferred embodiment, a clamp assembly 144 is pivotally coupled to
the upper end of the upright 136 and includes a cam surface 146
adapted to engage the upper end of the upper jaw 142 to urge it
into close relationship with the lower jaw 140. Mounted to the
upper and lower jaws 140, 142 are a plurality of rollers 148, 149.
The rollers 148 are laterally offset with respect to rollers 149 in
a staggered relationship. Each of the rollers 148, 149 includes a
circumferential groove intended to engage a surface of the incoming
wire to remove any coil or curvature in the wire in a vertical
plane.
[0041] Cantilevered from upright 136 and adjacent the upper and
lower jaws 140,142 may be a horizontally disposed plate 150 which
supports horizontally disposed jaws 152, 154. (See FIG. 2). The
horizontally disposed jaws 152, 154, like the vertically disposed
jaws 140, 142, support rollers 156, 158 configured to engage
opposite sides of the incoming wire. The jaws 152, 154 are spring
biased and aligned with each other such that jaw 152 may be moved
with respect to jaw 154. In this manner, the rollers 156, 158
contact opposite sides of the incoming wire and straighten the
wire, removing any coil or curvature in a horizontal plane such
that the wire fed to drive wheels 128, 130 is substantially
straight. A clamp 160 having a cam surface 162 and a locking nut
164 is used to engage and disengage jaw 152 to maintain it in a
desired position.
[0042] To facilitate operation of the assembly, a microprocessor or
computer control system (not shown) is integrated with the various
components. As briefly mentioned above, the linear actuators 48,
80, 100 are preferably pneumatically driven oil systems. Moreover,
the actuator 100 may also use a pneumatically driven system capable
of providing sufficient force to drive the sheared pin into the
aligned hinge barrels. The pilot valves driving the liner actuators
as well as the motor 114 on the drive assembly 110 may be
controlled by the computer control system. The computer control
system is also preferably connected to all of the proximity sensors
in the assembly for monitoring the operational position and status
of any particular component. Details of this control system will
not be disclosed herein as it is readily apparent that one of
ordinary skill in the art of numerical controls could design any
one of a number of different systems for controlling the automated
process of the punch and die assembly.
[0043] To reduce the chance of injury to the operators, it is
preferred that the entire assembly be enclosed within a cabinet
where the access panels are interconnected with sensors, such that
when opened, the system is shut down. It is anticipated one or more
light curtains could be incorporated at the end of the assembly
proximate the first press assembly to ensure that the operator's
hands are clear of the assembly before operation. Again, other than
briefly mentioning these components, they will not be described in
detail.
[0044] The invention also includes a method for assembling the two
leaves of a hinge including the steps of locating and retaining
within a first press assembly two leaves of a hinge in a
predetermined configuration on a seat such that the barrels of the
two hinge leaves are aligned; feeding a length of wire for use as a
pintle to a second press assembly; and receiving the length of wire
from the feed assembly and the second press assembly, and driving
the length of wire into the aligned barrels of the two hinge leaves
using a third press assembly. The locating step may further include
the steps of providing a frame assembly for supporting a linear
actuator in the first press assembly; and locating the two leaves
of the hinge in a punch and die assembly disposed beneath the
linear actuator for receiving the two leaves of the hinge. The
feeding step may include drawing a predetermined length of wire
from a spool of wire and supplying that length of wire to the
second assembly; and conditioning the length of wire into a
substantially straight configuration by removing any curvature.
Alternatively, the feeding step may include providing a magazine
containing at least one predetermined length of pintle to be
dispensed to the third assembly. The feeding step may further
include supplying the length of wire to a shear assembly; shearing
the length of wire to form a pintle; and driving the pintle into
the aligned barrels of the two hinge leaves. Moreover, the step of
locating the two leaves of the hinge in a punch and die assembly
may include positioning the two leaves of the hinge in a
predetermined configuration on a seat; urging a housing against the
two leaves of the hinge on the seat while driving the length of
wire into the aligned barrels of the two hinge leaves by the third
press assembly; and staking predetermined portions of at least one
of the hinge barrels about the predetermined length of wire to hold
it in the hinge.
[0045] According to another form of the invention a method is
provided for forming a hinge assembly, and includes the steps of
punching a first and second hinge leaves from a piece of stock,
each of said hinge leaves having knuckles substantially formed
thereon and configured to mate with like knuckles on the opposite
leaf. Placing the first and second hinge leaves in a predetermined
configuration on a seat and compressing the first and second hinge
leaves on the seat between a punch and die such that the knuckles
are aligned. Once aligned, ramming a pintle into the knuckles of
the first and second hinge leaves when compressed between said
punch and die. Finally, staking predetermined ones of the knuckles
so as to positively fix the pintle therein. The method may further
include the steps of drawing a length of wire from a spool of wire
and conditioning the length of wire to remove any curl or bends.
Following conditioning, feeding the length of wire into a measuring
station to define a predetermined length of wire. From there,
shearing the predetermined length of wire to form the pintle.
Finally, aligning the pintle axially with the knuckles prior to the
step of ramming. The method may further include preforming a
plurality of pintles, loading the plurality of pintles into a
magazine, placing the magazine into a receiver, and dispensing one
of the plurality of pintles into a position axially aligned with
the knuckles prior to the step of ramming.
[0046] More specifically, in the operation of the invention, the
punch and die assembly 20 may be disposed at the discharge end of
the progressive die assembly, or alternatively, may be located
elsewhere where the finished product from the progressive die
assembly is delivered. In one embodiment, an operator, standing at
the end of the punch and die assembly 20 proximate the first press
assembly30, places opposing halves of the hinge into the cradle or
seat 62 such that the barrels of the hinge leaves are aligned.
Prior to actuating the system, the operator has already inserted
one end of a spool of wire into the wire handling system 1 12, fed
it through the drive system 110, and inserted it into the shear
assembly 84 so that upon initiation of the system, the proper
length of wire pin is loaded in the shear assembly 84 to stake the
hinge.
[0047] Once the operator has the matching hinge leaves disposed
within the cradle or seat 62, the operator depresses a switch
causing the machine to cycle wherein the feed assembly 34 ensures
the proper length of wire pin is disposed within the shear assembly
84. Upon confirmation by a proximity sensor the appropriate amount
of wire has been feed into the shear assembly 84, linear actuator
80 drives piston 82 downwardly against shear plate 92 to shear the
wire pin in shear assembly 84 and causing it to fall into V-shaped
channel 86. Substantially simultaneously, the upper platen 56 of
the first press assembly 30 is moved downwardly by linear actuator
48 to place the punch tool assembly 64 into engagement with the
hinge barrels of the two hinge leaves located in the cradle 62.
Once the upper platen 56 and punch assembly 64 locate the two hinge
leaves, actuator 100 drives the wire pin in the V-shaped channel
guide 86 into the aligned hinge barrels. At this point, the barrels
of the hinge are ever so slightly open to easier receive the pintle
therein. Substantially immediately following the insertion of the
wire pin into the hinge barrels, staking pins disposed within the
punch tool assembly 64 are actuated, causing them to depress
certain ones of the interlocking hinge barrels to secure the pintle
in place. Once the process is complete, and the proximity sensors
indicate that the method has been completed, the upper and lower
platens of the first press assembly separate wherein the hinge
assembly may be removed manually, or in a preferred embodiment, is
ejected from the cradle 62 by an actuator assembly (not shown) to
fall through a hole in the table and into the bin 38. In this
manner, the operator is already poised to insert another pair of
matching hinge leaves on the cradle 62 for the next operation.
[0048] As briefly mentioned at the beginning of this description,
it is believed the method of forming the hinge leaves in the
progressive die assembly also presents a novel process. The
progressive die assembly receives a continuous sheet of steel,
inserted at one end wherein the first stamping creates an indexing
hole in the steel. At the second position, the progressive die
assembly punches bolt holes in the steel which will be used to
attach the hinge to the substrate. Following the punch of the bolt
holes, the conveyor indexes the sheet of steel to the third station
where each of the holes is punched to create a chamfer. Following
the chamfer, the conveyor indexes the sheet of steel to the fourth
and fifth stations where the fingers for the hinge barrels are
sequentially punched. It is at these two stages of the process
where the perimeter of each hinge leaf is formed, interconnected to
each other by a web of steel. When conveyed to the seventh through
tenth stations of the progressive die assembly, the contours of
each hinge leaf are formed as well as the progressive rolling of
the fingers to produce the interlocking barrels of each hinge leaf.
At the twelfth station, additional punches are added to
specifically locate each hinge plate on the substrate. The
fourteenth station is where the two hinge leaves are separated by
punching out the web which also disconnects the hinge plates from
the continuous sheet of steel.
[0049] The invention described above has included a continuous wire
feed assembly, where the length of the wire is measured prior to
being sheared, and then driven into the aligned barrels of the
mating hinge leaves. However, it is contemplated the pintles of the
hinge assembly may be prefabricated, rendering the need to measure
and sheer the wire unnecessarily. This alternative is provided for
in the alternate embodiment of the invention illustrated in FIGS.
9-12. For the sake of clarity, only those portions of the adjoining
assembly will be shown for reference. For details on the adjoining
assemblies, please refer to the FIGS. 1-6.
[0050] Referring to FIGS. 9-12, the alternate embodiment 200 of the
invention presents a less complicated yet more versatile assembly.
The most obvious modifications are the removal of the second or
intermediate press assembly 32 as well the feed assembly 34 shown
in FIGS. 1-6 and replaced with a magazine described below. Rather
than a continuous wire feed, precut pintles are used for each hinge
assembly. It is contemplated the pintles are pre-manufactured and
delivered in bulk to the hinge assembly machine. For example, it is
contemplated that steel rod of specific dimension is cut to
predetermined lengths in a separate press and coated with a
lubricant to facilitate insertion into the hinge barrels during the
assembly process. In particular, it is contemplated each of the
pintles may be coated with a polytetrafluoroethylene such as sold
under the brand name Teflon available from DuPont Corporation. The
coated pintles may then be packed in bulk and delivered to the
hinge assembly location.
[0051] The alternate embodiment of the hinge assembly machine 200
includes a feed assembly 202 which includes a magazine 204
configured to receive and dispense a predetermined number of the
pre-manufactured pintles. The magazine 204 may take on anyone of a
number of different forms, but in general, includes a first box end
206 rigidly attached to a back plate 208, and a second opposing box
end 210 spaced therefrom and configured for sliding movement along
the back plate 208. Horizontally mounted to the back plate 208 are
two spaced apart and parallel tracks 212, 214 which pass through
corresponding channels 216,218 in box end 210 to help align box end
210 and keep it parallel to box end 206. The intermediate area
between the two box ends 206, 210 is preferably open in order to
permit the operator to grab hold of a quantity of pintles and
remove them from the magazine 204 should it be necessary, such as
making a change in pintle size, or re-filing the magazine.
[0052] As noted earlier, it is desirable for box end 210 to be
translatable in a horizontal direction with respect to box end 206
and parallel to back plate 208, primarily to accommodate for
preferred variations in the pintle size. Toward this end, a
horizontal slot 220 is defined in back plate 208. In turn, a bolt
222 passes through box end 210 such that the threaded end 224
extends through slot 220. There, a crank 226 is received, and when
turned, tightens the box end 210 and holds it in position.
[0053] Attached to the lower portion of the back plate 208 of the
magazine 204 is a dispensing member 230. Preferably dispensing
member 230 is in the form of a right circular cylinder having a
longitudinal axis oriented horizontally and substantially directly
below box ends 206 and 210. Coincident with the longitudinal axis
of the dispensing member 230, and extending from opposite ends
thereof are axles or spindles 232,234, each journaled in a bearing
block 236,238, respectively. Each of the bearing blocks 236, 238
are in turn mounted to the back plate 208. Axle or spindle 234
shown in the right hand portion of FIG. 9 is slightly longer such
that it extends beyond bearing block 238. There, the end of the
spindle 234 is attached to a spur gear 240 or similar drive
mechanism to affect rotation of the dispensing member. Details of
the preferred drive mechanism will be described in greater detail
below. Regardless of the specific drive mechanism, the dispensing
member 230 is free to rotate about a longitudinal axis.
[0054] Defined lengthwise along the exterior surface of the
dispensing member 230, and parallel to its longitudinal axis is a
slot or channel 242 and dimensioned to receive a single one of the
pintles retained between the box ends 206, 210. In the preferred
embodiment, each box end 206, 210 has converging inner walls 244,
246, the distance between them being wider at the upper end 248 and
becoming narrower at the lower end 250 such that at the outlet 252,
a single pintle is permitted to pass there through. The outlet 252
at the lower end 250 is positioned directly above the longitudinal
slot 242 in the dispensing member 230.
[0055] The magazine 204 is slidably received within a bracket or
magazine receiver 260 which is mounted to the table 36. The bracket
or receiver 260 is located substantially adjacent the V-shaped
channel 86 and is configured to hold the magazine at a
predetermined height above the V-shaped channel 86 such that
pintles dispensed from the magazine 204 fall to the bottom of the
V-shaped channel 86 prior to being inserted into the barrels of the
hinge leaves. The bracket or receiver 260 includes a base member
262 attached to the table 36. The base member 262 supports an
upright 264, braced at opposing ends with the base member 262 by
bulkheads 266 and 268. Attached along the front face 270 of the
upright 264 at the opposite vertical sides are gibs 272 and 274,
which, together with the upright, define two channels 276 and 278
configured to slidably receive the edges of the back plate 208. The
downward movement of the back plate 208 within the gibs 272, 274 is
restricted by anyone of a number of different forms of stops. These
include a separate piece of bar stock attached to front face 270,
or a shoulder machined into the front face, depending upon
individual preference. The primary purpose of the stop is to
properly locate and fix the dispensing member 230 at the desired
height adjacent the V-shaped channel 86. Alternatively, it is
contemplated the dispensing member 230 may be separate and apart
from the magazine and fixed independently to the bracket 260 so
always to be at the proper height and horizontal position. In this
configuration, each magazine may have a sliding panel at the bottom
which is removed once the magazine is in position. The removal of
the slide would permit the pintles to falls, one by one, into the
slot formed in the dispensing member.
[0056] Regardless of the specific magazine configuration, it is
contemplated an actuator mechanism 280 may be operably coupled to
the spur gear 240 to actuate the dispensing member 230 in a rotary
fashion to dispense the pintles. Such an actuator is shown
generally in FIG. 10 and is mounted to the table 36. The actuator
280 may be coupled to the drive member 240 in any one of a number
of different ways, but the preferred method is a direct coupling,
either by way of spur gear 282 extending from the actuator 280 and
interconnected via an idler gear 284. Alternatively, a similar
arrangement could be provided, but rather than gear teeth, each of
the gear or rollers could be operably coupled by a friction
coupling such as rubber wheels. Other arrangements could also be
utilized including belts and the like. As shown in the FIG. 12, the
actuator 280 is mounted to an upright 286 which extends from a base
288 attached to table 36. Bulkheads such as 290 may be used to
strengthen the connection between the upright 286 and the base 288
similar to the other mounting systems described above.
[0057] The operation of the embodiment shown in FIGS. 9-12 is
substantially similar to that described above, but rather than the
operator inserting the lead of a continuous length of wire into the
feed mechanism, a magazine 204 containing the predetermined size
and number of pintles is loaded into the receiver 260 such that
upon each sequence of operation, a single pintle is loaded onto the
V-shaped channel guide 86. From there, each is driven into the
aligned barrels and staked into position as in the previous
embodiments.
[0058] One should take notice that in the above description,
certain stations are not mentioned to have any operations. The
omitted stations are considered to be idle stations in order to
provide sufficient separation distance for the various operations
being performed on the continuous sheet of steel. The advantages in
the aforementioned method specifically include the forming of the
holes for the bolts prior to the forming of any contours. This
change in procedure substantially reduces deformation in the
finished product, provides closer tolerances and better fit. In the
prior methods of manufacturing hinges, the contours were often
formed prior to the punching of the bolt and locating holes. When
the bolt and locating holes were formed, the punching process
tended to draw metal into the punches and produce a deformation in
the overall contour. As a result, the hinge did not fit well or
flush with the underlying substrate.
[0059] The above description is considered that of the preferred
embodiments only. Modifications of the invention will occur to
those skilled in the art and to those who make or use the
invention. Therefore, it is understood that the embodiment shown in
these drawings and described herein are merely for illustrative
purposes and not intended to limit the scope of the invention,
which is defined by any claims in a subsequent or related
application and interpreted according to the principals of patent
law, including the doctrine of equivalence.
* * * * *