Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
CA 02426748 2003-04-16
METHOD AND APPARATUS FOR MANUFACTURING HINGES
CROSS REFERENCE TO RELATED APPLICATION
This application is related to provisional patent application serial number
S 601284,752, filed on April 18, ? 001, the contents of which are incorporated
herein by
reference.
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates generally to a method and apparatus for assembling
l 0 components, and more particularly to a method and apparatus for
manufacturing and
assembling hinges.
Description of the Related Art
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
15 knuckles were rounded over a pre-positioned pintle by hammer or ane or more
press
operations. Later, with mass production, the hinge leavea 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
20 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.
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
?S 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 al:>o after the pintle has
been
trapped. This shearing method of the entire hinge assembly also introduces
similar
~0 contortions and deformations in the assembly, also resulting in poor
operation.
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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.
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. 'rhe instant :invention solves those
needs.
SIJ1VI~IAR~ OF 'TTTE TNVEN'~'~ON
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
embodi-
ment, 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.
According to one aspect of the invention, are 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 tu~o 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.
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In a further form of the invention, the first assembly includes a frame
assembly; a press attached to the frame assembly; ands 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 w ire 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
1 S assembly for ejecting the interconnected hinge leaves from the seat.
The invention also includes a method for assembling the two leaves of a hinge
including the steps of locating and retaining within a fir;>t 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 leav es 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.
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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 foam a pintle; and drip°ing the pintle into the
aligned barrels of
the two hinge leaves. Woreover, 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.
According to another form of the invention a method iS provided for forming
a hinge assembly, and includes the steps of punching a f rst 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
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receiver, and dispensing one of the plurality of pintles into a position
axially aligned
with the knuckles prior to the step of ramming.
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 a;~ially aligned with the
knuckles and
with said first ram.
A better understanding of the invention will be attained by reference to the
following drawing figures as well as the subsequent detailed written
description ofthe
different embodiments of the invention.
BRIEF DESCRIPTION OF TFIE DRAWING FIGURES
FIG. 1 is a schematic side elevation of one embodiment of the invention;
FIG. 2 is a schematic plan view of the invention shown in FIG. 1;
FIG. 3 is an end elevation of the invention shown in FIG. 1;
FIG. 4 is an end view of the intermediate press assembly shown in FIG. 1;
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FIG. 5 is a bottom plan view of the punch assembly shown in FIG. 3;
FIG. b is a plan view of the die assembly shown in FIG. 3;
FIG. 7 is an enlarged side elevation view of the shear assembly shown in
FIGS. l, 2, and 4;
FIG. 8 is an enlarged end section view of the shear assembly shown in FIG.
FIG. 9 is a schematic side elevation of another embodiment of the invention;
FIG. I O is a schematic plan view of the invention shown in FIG. 9;
FIG. 11 is an end elevation of the invention shown in I~IG. 9; and
IO 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 El~IBODIh~IENT OlF TIRE INVENTION
For purposes of the following description, the terms "u~~per," "lower,"
"left,"
I S "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
20 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 t~~ 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
25 different requirements and components.
Referring generally to the attached drawing figw-es, an apparatus is
pi°ovided
for interconnecting taro leaves of a hinge by automatically inserting and
clamping a
pin in the baurels of at least two leaves, comprising in combination a first
assembly
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for holding the two hinge leaves together such that the lbarrels 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 a;Dsembly 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.
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 i:or 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
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for conditioning the length of wire to remove any curl or bends, an assembly
for
feeding the length of wire into a measurirEg station t<> 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 fir st ram.
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 var ious punch and die sets contained within the progressive die.
Details
on the progressive die assembly will not be provided in. this description.
However,
1 S 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, ;end substantially
automated
production of work pieces than should the steps be done separately.
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 tl ee
assemblies {30, 32, and 34) are preferably mounted te~ a work surface or table
36
disposed at a predetermined height above a reference plane such as the floor.
The
table 35 is preferably designed so as to receive one or' more bins 38
positioned to
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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.
In one embodiment of the invention, it is contemplated the first press
assembly
30 (FIGS. l 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
ofthe
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.
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 upfer platen 56 supported
above
a lower platen 58 by a plurality of telescoping and biased guides, columns or
posts 60
intended to keep the tvvo 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.
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
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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 alsa 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 ~8 permits seats 62 of different dimensions
to be
used.
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.
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
predeteumined 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. l,
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
2~ a cross member 76 (FIGS. I 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.
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Disposed beneath piston 82, and supported by th,e lover 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
S assembly 84 is mounted on the Iower 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 ju;~t 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 th.e 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.
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 1'eavea. As illustrated in
FIG. 4, the
V-shaped channel guide 86 includes a longitudinal channel or slot 106 located
at the
bottolll through which the cauriage 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.
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 in<;Iudes 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 I22 and bulkhead 124. hxtending below the
transmis-
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sion 116 is a drive i26 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, t~vo 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 cachet-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 :hear assembly 84.
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 1 I2 may
include a base plate 134 for supporting an upright 136 bolstered by a bulkhead
138.
1 ~ 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 Iower 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 I42 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
2~ intended to engage a surface of the incoming wire to remove any coil or
curvature in
the wire in a vertical plane.
Cantilevered from upright 136 and adjacent the upper and lower jaws 140, I42
may be a horizontally disposed plate 150 which supports horizontally disposed
jaws
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152, 15=1. (See FIG. 2). The horizontally disposed jaw:; 152, i54, 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 1~2 may be moved with respect to,jaw 154. In this manner,
the
rollers 1 ~6, 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 l~aaving a cam surface
162 and
a locking nut 164 is used to engage and disengage jaw 152 to maintain it in a
desired
position.
To facilitate operation of the assembly, a microprocessar or computer control
system (not shown) is integrated with the various comp~Dnents. 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 ofthis 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.
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
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CA 02426748 2003-04-16
before operation. Again, other than briefly mentionin'; these components, they
will
not be described in detail.
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 i.n 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 supply ing 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 tI-~e 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 pir.~tle 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 pos~.tioning 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 ~.vhile driving the length of wire into the aligned bawels
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.
According to another forni of the invention a method is provided for forming
a hinge assembly, and includes the steps of punching a. first and second hinge
leaves
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from a piece of stock, each of said hinge leaves having knuckles substantially
for med
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, rarruning a pintle into the
knuckles
of the first and second hinge Ieav es when compressed between said punch and
die.
Finally, staking predetermined ones of the knuckles :>o 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
I S receiver, and dispensing one of the plurality of pintles into a position
axially aligned
with the knuckles prior to the step of ramming.
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 alteunatively, may be located elsewhere where the finished product from the
progressive die assembly is deliv eyed. In one embodiment, an operator,
standing at
the end of the punch and di.e assembly 20 proximate the first press
assemb1y30, places
opposing halves of the hinge into the cradle or seat b2 such that the barrels
of the
hinge leaves are aligned. Prior to actuating the system, the operator has
already
inseuted one end of a spool of wire into the wire handling system 112, fed it
through
the drive system 110, and inseuted it into the shear assembly 84 so that upon
initiation
of the system, the pr open length of wire pin is loaded in the shear assembly
84 to stake
the hinge.
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CA 02426748 2003-04-16
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
S 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 S6 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 th.e cradle 62. Once the upper platen S6 and punch
assembly
64 locate the two hinge leaves, actuator I00 drivea 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.
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
2S 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
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CA 02426748 2003-04-16
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 bars els are seduentially punched. It is at these two stages of the
process where
the perimeter of each hinge leaf is forn~ed, 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
~ 0 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.
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 ban °els 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.
Refenr ing to FIGS. 9 - 12, the alternate embodiment 200 of the invention
presents a Iess complicated yet more versatile assembly. The most obvious
modifications ar a the removal of the second or intermediate press assembly 32
as well
the feed assembly 34 shown in FIGS. I - 6 and replaced with a magazine
described
below. Rather than a continuous wii°e feed, precut pintles are used for
each hinge
assembly. It is contemplated the pintles are pre-manufactured and deliv eyed
in bulk
to the hinge assembly machine. For example, it i;> contemplated that steel rod
of
specific dimension is cut to predetermined lengths ire a separate press and
coated with
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CA 02426748 2003-04-16
a lubricant to facilitate insec-tion 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.
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-manufactur ed pintles. The magazine 204 may
take
on anyone ofa 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 2I0 spaced
therefrom and conf gored for sliding movement along the back plate 208. I-
Iorizon-
tally 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 2I 0 to help
align box
end 2I0 and keep it parallel to box end 206. The intermediate area between the
two
I S box ends 206, 2I 0 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.
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 21 d 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.
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 2I0. Coincident with the longitudinal axis of
the
dispensing member 230, and extending from opposite ends thereof are axles or
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spindles 232, 234, each journaled in a bearing block f,36, 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 o:Pthe spindle 234 is
attached to
a spur gear 240 or similar drive mechanism to affect i°otation 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.
Defined lengthwise along the exterior surface of the dispensing member 230,
and parallel to its longitudinal axis is a slot or channel ~?42 and
dimensioned to r eceive
a single one of the pintles retained between the box ends 206, 210. In the
pi°efen-ed
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.
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 adj acent 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 rrlember 262 supports an
upright
264, braced at opposing ends with the base member a?62 by bulkheads 266 and
268.
Attached along the front face 270 of the upright 264 at the opposite vertical
sides are
gibe 272 and 274, which, together with the upright, define two channels 276
and 278
configured to slidably receive the edges of the ba<~k plate 208. The downward
movement of the back plate 208 within the gibe 272, 274 is restricted by
anyone of
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CA 02426748 2003-04-16
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 mennber 230 may be sepaxate
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 cor;~figuration, 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.
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. I O and is mounted to the table 3~. The actuator
280 may
be coupled to the drive member 240 in any one of a number of different ways,
but the
prefers ed method is a direct coupling, either by way o~f 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. ~ther
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 u~ced to strengthen the
connection
between the upright 28b and the base 288 similar t;o the other mounting
systems
described above.
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
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CA 02426748 2003-04-16
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.
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 perfornled on the continuous sheet of steel. The advantages in the
aforemen-
tioned 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 wei°e 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.
The above description is considered that of the preferred embodiments only.
Modifications of the invention will occur to those skilled in the a.ut and to
those Vvho
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.
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