Method and apparatus for forming a leaf spring eye

Abstract: Apparatus (100) and method are provided for forming an eye at the end of a heated leaf spring blank (2). Apparatus (100) includes a forming plate (16) operative to move angularly downwardly against a cantilevered portion (10) of blank (2) and roll it about a retractable rotary eye pin (5) to form the eye. Apparatus (100) includes neutralizing the force created by forming plate (16) against blank (2) during the rolling operation and further preferably includes a scarf blade (14) operative to move angularly to scarf or shape the end of portion (10)prior to the rolling operation.

Description: INTRODUCTION This invention relates generally to method and apparatus for forming an eye at the end of a vehicular leaf spring blank and more particularly to method and apparatus employing angular downward motion to roll a predetermined length of the end of a heated leaf spring blank about a rotary eye pin to form the eye. BACKGROUND OF THE INVENTION Eyes have long been incorporated at one or both ends of a vehicular leaf spring to provide a means of support between the frame and axle of the vehicle. Generally the eyes are adapted to receive bushings (more commonly elastomeric bushings) that in turn are adapted to be secured to the frame by means of a threaded pin or the like to provide pivotal support between the axle and the frame of which one example can be found in United States Patent No. 5,129,671, assigned to the assignee of the present invention. Little has been reported in the development of machines to form an eye at the end of leaf springs since the early days of hand forging of heated leaf spring blanks. However, one example of such an automatic machine is disclosed in United States Patent no. 3,967,487 (nearest state of the art). The apparatus disclosed however requires the complex positioning of a goose neck, movement of a scarf blank to scarf the end of a heated leaf spring blank which is clamped to a base, followed by initial bending by a scroll die, followed by insertion of an eye pin, and then forming the eye by opposed motion of a scroll die surface and scroll die. The present invention provides a simpler and more economical method and apparatus for forming an eye at the end of a heated leaf spring blank by eliminating the goose neck die and the pair of opposed scroll dies and replaces them with a process that does not require a goose neck die and utilizes a singular forming plate that is operative to roll a cantilevered portion of the heated blank about an already positioned rotary eye pin and thereby eliminate the need for costly scroll dies involving arcuate surfaces. SUMMARY OF THE INVENTION Accordingly, it is an object of this invention to provide a method and apparatus for forming an eye at the end of a vehicular leaf spring. It is another object of this invention to provide apparatus operative to form an eye at the end of a vehicular leaf spring blank without the need for costly dies hereto after used for such purposes in the past. These objects are achieved by the method as defined in claim 1 and the apparatus as defined in claim 4. Preferred embodiments of the invention are defined in the dependent claims. BRIEF DESCRIPTION OF THE DRAWINGS FIGURE 1A-1C are partial schematic diagrams illustrating the sequential movement of apparatus elements; FIGURE 2 is a partial side elevation view of one embodiment of a leaf spring eye; FIGURE 3 is a partial side elevation view of another embodiment of a leaf spring eye; FIGURE 4 is a side elevation view of a preferred embodiment of apparatus 100; FIGURE 5 is a view of apparatus 100 taken along view line 5-5 in FIGURE 4; and FIGURE 6 is a view of apparatus 100 taken along view line 6-6 in FIGURE 4. SUMMARY OF SOME PREFERRED EMBODIMENTS The principles involved in the forming method are illustrated in FIGURES 1A-1C in which the element numerals are also used in FIGURES 4-6 of the apparatus drawings for easier reference. In FIGURE 1A a heated leaf spring blank 2 is located upon and releasably secured to a first stationary support surface 32 by clamping means such as clamp 7. Leaf spring blank 2 is made from a resilient steel alloy well known to those skilled in the art that is suitable for leaf spring suspension systems and is heated to a working temperature that is characteristically in the order of about 704-816°C (1300-1500 °F). Leaf spring blank 2 is also supported by a rotary eye pin 5 and a second support surface 4 that are respectively mounted for movement in unison with forming damp mechanism 8. Forming clamp mechanism 8 is able to move upwardly and downwardly as well as horizontally in opposite directions as shown by the arrows in FIGURE 1A. Support surface 4 and rotary eye pin 5 are able to move horizontally and support surface 4 can also move upwardly and downwardly as well. A portion 10 of leaf spring blank 2 is cantilevered away from eye pin 5 and is of a length predetermined to allow a scarf cut at the cantilevered free-end of leaf spring blank 2. When initially held in a working position, rotary eye pin 5 is also supported by an arcuate support section 18 of frame 12. Frame 12 is movable angularly upwardly and downwardly with respect to a base in opposite directions as shown by the arrows in FIGURE 1A. Frame 12 carries a scarf blade 14 and a forming plate 16. Scarf blade 14 and forming plate 16 are preferably movable with respect to frame 12. In the sequence shown in FIGURES 1A and 1B, scarf blade 14 has moved angularly downwardly to engage and scarf the end of leaf spring blank 2 which in effect has shaped or formed the end of blank 2 so that it conforms to the underside of blank 2 after the forming operation. In the sequence between FIGURES 1B and 1C, frame 12 has continued to move angularly downwardly as shown by the arrow enabling forming plate 16 to engage the side of cantilevered portion 10 facing away from eye pin 5 and then roll the cantilevered portion 10 of blank 2 about eye pin 5 as shown by the arrow. While forming plate 16 rolls cantilevered portion 10 about eye pin 5, it moves in a direction down and towards the viewers right in FIGURE 1C exerting a force F 1 on eye pin 5. It is for this reason that forming damp mechanism 8, support surface 4 and rotary eye pin 5 are urged towards the viewer's left with Force F 2 to provide full contact between forming plate 16 and that portion of blank 2 rolled about eye pin 5 as shown by the arrows in FIGURE 1C. It is to be noted that arcuate support surface 18 of frame 12 is not required in the forming operation between FIGURES 1B and 1C as it functions primarily to provide support for eye pin 5 during the angular downward engagement with scarf blank 14 to protect roller bearings and the like that are employed to journal eye pin 5 for rotation. FIGURES 2 and 3 illustrate two (2) different kinds of leaf spring eyes that can be formed by the method of the present invention. In FIGURE 2, the end of leaf spring blank 20 has been rolled about the rotary eye pin of the apparatus of the invention to form eye 22 and its end has been scarfed to conform with the underside of blank 20 such as referenced by numeral 24. In this case the center of eye 22 is below the underside of blank 20. In FIGURE 3, an eye 28 has been formed in a leaf spring blank 26 by the method of the present invention with its end scarfed as referenced by numeral 30 but in this case the center of eye 28 is in substantial alignment with the neutral bending axis of blank 26 (not referenced). Thus, various configurations can be made at the eye location either by raising or lowering support surface 4, relative to location of rotational axis of eye pin 5 and/or applying a force against plate 2 adjacent the outer perimeter of eye pin 5. A preferred embodiment of apparatus operative to provide the method of the invention is referenced by numeral 100 in FIGURES 4-6. In FIGURE 4 apparatus 100 includes a base 32 upon the top of which are mounted slide rails 36 and 36' (the later is shown on FIGURE 6). A first frame 34 is slidably mounted in rails 36 and 36' for movement in opposite directions as shown by the arrows in FIGURE 4. A support surface 4 is mounted on frame 34 for movement therewith in opposite directions as shown by the arrows in FIGURE 4. Support surface 4 is preferably positionable upwardly and downwardly preferably by means of an electric motor 60 and gear boxes 54 and 58 that are interconnected by chain 56 as best shown in FIGURE 5. As earlier described, a heated leaf spring blank 2 rests upon surface 4 and is held in contact with eye pin 5 by forming clamp mechanism 8 that is movable upwardly and downwardly preferably by means of an hydraulic cylinder 48, as shown by the dashed lines in FIGURE 4. All of rotary eye pin 5 forming clamp mechanism 8 (including cylinder 48) and support surface 4) are mounted on frame 34 so that they move in unison in opposite directions therewith as shown by the arrows in FIGURE 4. The rotary mounting of eye pin 5 is best seen in FIGURES 5 and 6 where the opposite ends of pin 5 are journaled for rotation by journal housings 64 and 66 respectively that in turn are mounted on frame 34 as earlier described. Rotary eye pin 5 is also insertable and retractable so that it can be first positioned and then retracted after the eye has been formed. The retraction of eye pin 5 is preferably accomplished by having journal housing 66 slidingly mounted on frame 34 and movable in opposite directions as shown by the arrows in FIGURE 6 preferably by means such as hydraulic cylinder 62 shown in FIGURES 5 and 6. A second frame 42 (shown in FIGURE 4) is fixedly secured to base 32 and is adapted to carry a third frame 12 that is angularly movable in opposite directions as shown by the arrows. Frame 12 includes support surface 18 (referenced in FIGURE 1A and 1C but not shown in FIGURE 4) and carries scarf blade 14 and forming plate 16 described earlier with respect to shown in FIGURE 1. Frame 12 is angularly movable with respect to base 32 preferably by means of being secured to a pair of spaced-apart ball nut tracks 68 and 70 that in turn are threadingly engaged with a rotary ball nut screw 44 that is rotated preferably by means of an electric motor 46. Hydraulic cylinder 52 is secured to frame 12 as the preferred means for moving scarf blade 14 and forming plate 16 in opposite directions along frame 12. It is to be understood that, although it is preferable to move both forming plate 16 and scarf blade 14 in unison by means of a singular power source such as hydraulic cylinder 52, they may be moved by separate power sources or both may be fixedly secured to frame 12 and positioned such that the angular movement of frame 12 alone enables either or both the scarfing and rolling operation to occur. Also shown in FIGURE 4 a flexible track 50 is provided that is operative to carry flexible hydraulic hoses and the like to convey fluid power between hydraulic motor 46 and cylinder 52. Apparatus 100 is provided with means for urging frame 34 in an opposite direction to the direction (towards the viewer's right in FIGURE 4) imposed upon eye pin 5 when the cantilevered portion 10 of leaf spring blank 2 is engaged by forming plate 16 as it is moved angularly downwardly so that it is able to apply a force imposed upon frame 34 by forming plate 16 as previously described with respect to Force F 1 in FIGURE 1C. The means for urging frame 34 towards the viewer's left in FIGURE 4 is preferably provided by one or more hydraulic cylinders such as cylinders 40 and 40' that are respectively fixedly secured to base 32 by means of a frame 38 or the like and are operable to urge frame 34 (including support surface 4, forming damp mechanism 8, rotary eye pin 5) towards the viewer's left to counteract the movement of frame 34 towards the viewer's right as forming plate 16 engages and rolls cantilevered portion 10 of blank 2 about eye pin 5 for a predetermined circumferential length as previously described with respect to Force F 2 in FIGURE 1C. Apparatus 100 also preferably includes one or more bumpers such as the spring loaded bumper 41 shown in FIGURE 4 that, like hydraulic cylinders 40 and 40', have one end secured to stationary frame 38 and an opposite end to movable frame 34. Such bumpers are operative to minimize shock and linear oscillation during operation of apparatus 100. Although it has been found that frame 12 (and scarf blade 14 and forming plate 16) are operative to move angularly upwardly and downwardly at a preferred included angle of from about 30° to vertical, other angles may be employed that enable scarf blade 14 to move angularly downwardly to scarf (dress or shape) the end .of cantilevered portion 10 of leaf spring blank 2 in the manner desired and also enable forming plate 16 to move angularly downwardly to engage and roll cantilevered portion 10 about eye pin 5 while providing a force counteracting the force created on the eye pin by the forming plate during the rolling operation. It is also to be understood that the present invention includes embodiments that enable the simultaneous or sequential formation of eyes at opposite ends of heated leaf spring blanks.

Claims: A method of forming an eye (22;28) at an end of an elongate leaf spring blank (2;20;26) having a longitudinal axis, said method including the steps of: heating blank (2;20;26) to a predetermined temperature; holding heated blank (2;20;26) in a working position with a cantilevered portion (10) extending for a predetermined length from a rotary eye pin (5) having a central rotational axis disposed in transverse relationship to the longitudinal axis of blank (2;20;26); engaging and rolling cantilevered portion (10) about rotary eye pin (5) for a predetermined circumferential length with a forming plate (16) which is moved angularly downward while urging eye pin (5) in a direction towards forming plate (16); and removing eye pin (5) from eye (22). The method of claim 1 including the step of scarfing an end (24;30) of blank (2;20;26) with a scarf blade (14) to conform end (24;30) with the bottom surface thereof prior to forming eye (22). The method of claim 2 wherein scarf blade (14) is operative to move angularly downwardly during the scarfing operation. An apparatus (100) for forming an eye (22;28) at an end of a heated elongate leaf spring blank (2;20;26) having a longitudinal axis, said apparatus including: a base (32) having means for releasably securing blank (2) thereto; a first frame (34) slidably mounted on base (32); a second support surface (4) mounted on first frame (34) for supporting blank (2) in a working position with a section (10) thereof in overhanging relationship to support surface (4); a rotary eye pin (5) mounted on first frame (34) such that eye pin (5) is in contact with the underside of overhanging section (10) at a location providing a cantilevered portion of blank (2;20;26) of prescribed length therebeyond; a forming clamp mechanism (8) mounted on the first frame (34) and operative to hold blank (2;20;26) against either or both eye pin (5) and second support surface (4) with a section (10) thereof in overhanging relationship to frame (32) during the eye forming operation; a second frame (42) fixedly secured to the base (32); a scarf blade (14) mounted on second frame (42) and downwardly engageable with the end of cantilevered portion (10) of the blank (2;20;26); a forming plate (16) mounted on second frame (42) and downwardly engageable with the side of blank (2;20;26) cantilevered portion facing away from the eye pin (5); means for moving scarf blade (10) angularly downward into scarfing engagement with the end of cantilevered portion (10) of blank (2;20;26) and subsequent release therefrom upon completion of the scarfing operation; means for moving forming plate (16) angularly downward into contacting engagement with the side of cantilevered portion (10) facing away from eye pin (5) and then rolling cantilevered portion (10) of blank (2;20;26) about eye pin (5) for a predetermined circumferential length to form eye (22;28) and subsequent release therefrom; and means for removing eye pin (5) from eye (22;28); said apparatus (100) operative such that blank (2;20;26) and second support surface (4) and eye pin (5) and the forming clamp mechanism (8) are urged towards forming plate (16) while forming plate (16) rolls blank (2;20;26) cantilevered portion (10) about eye pin (5). The apparatus of claim 4 wherein scarf blade (14) and forming plate (16) are mounted on a third frame (12) that is slidingly engaged with second frame (42). The apparatus of claim 6 wherein scarf blade (14) is movable relative the third frame (12) and forming plate (16). The apparatus of claim 5 or 6 wherein third frame (12) includes means for supporting eye pin (5) during the scarfing operation. The apparatus of any of claims 5 to 7 wherein support surface (4) is a vertically positionable support surface.

Inventors: RIVARD MICHAEL, RIVARD, MICHAEL
Applicants: OXFORD SUSPENSION INC, OXFORD SUSPENSION, INC.
Application year: 1997
Main classification: B21D53
IPC codes: B60G11, B21D53, B21D7, B21D11