Patent ID: 12257657

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

Referring toFIGS.1-10generally, there is provided a tool head assembly, shown generally at10, in accordance with the present invention. The tool head assembly10includes at least one cam12, drive shaft14or “stationary shaft”, movable slide16, and a oneway locking bearing. The head assembly10has the internal cam12, which spins freely on the drive shaft14in one direction and locks onto the shaft14in the other direction. That cam12rotates against the movable slide16forcing it to move away from the drive shaft14opening a gap, shown generally at18, between rollers, e.g., a first and second roller20,22or “post”.

It is understood that the drive shaft14is preferably a rotating shaft, however, the shaft14is stationary in that the shaft14does not move in a lateral direction. The drive shaft14keeps the position of the first roller20, including, as the second roller22selectively translates away from or toward the first roller20to change the gap18. As the second roller22moves toward and away from the first roller20, which is stationary, the gap18between the rollers20,22decreases and increases (closes/opens), respectively.FIGS.7and9generally depict an exemplary narrowed gap18compared to the more open position of exemplaryFIG.8.

Preferably, the developed tool head assembly10utilizes the ability to program a predetermined drive to a specific process depending on the application.

A controller24(seeFIG.9) is programmable to have the drive rotate in one direction for a predetermined set time period (e.g., generally about 5-60 seconds, typically 5-30 seconds, preferably 2-20 seconds, most preferably 2-10 seconds) when a trigger26or “button” is actuated (e.g., pulled, compressed, pushed, slid, rotated, etc) then reverse the rotation to begin the crimp process. The controller24utilizes wireless or hardwired protocols, preferably, wireless. Preferably, the controller24operably incorporates with at least one sensor, electric sensor, gyroscope, acceleramator, and/or camera, etc.

The start rotation of the drive rotates the cam12and opens the roller gap18. The forward rotation then allows the cam12to swing, closing the gap18and allowing translating the rollers20,22around the seal (e.g., seal or weatherstrip of a lift gate, car trunk, front side doors, rear side doors, windshield, flange or any other predetermined part, any predetermined cover part to secure the cover part to any predetermined structural member). This design allows the head tool assembly10to function similarly as a pneumatic style tool, but eliminates the air cylinder and related pneumatic hoses and valve making the tool head assembly10smaller. Preferably, at least the second roller22spins while applying the seal, as indicated inFIG.9. Most preferably, the second roller22spins and the first roller20does not spin while applying the seal.

Preferably, the system allows the controller24to communicate with any production feedback device66or system66(e.g., any OEM production system) to verify and operably communicate feedback to a database, any other predetermined operable data compiler, and/or tool operator in real time that the tool is/has been used and is/has been used properly according to predetermined parameters, e.g., used in the correct predetermined orientation(s), angle(s) and/or position feedback, used for the correct predetermined amount of time, used at correct predetermined speed, used at correct predetermined pressure or force, etc.

At least one biasing member28, preferably two biasing members28,30(most preferably, spring(s)), biases the movable slide16against the cam12in the closed direction to urge the first and second rollers20,22together. Most preferably, to urge the second roller22toward the first roller20and the first roller20is laterally stationary.

The drive shaft14preferably extends through an aperture formed in a block32and is operably coupled to the first post20. The block32is operably coupled to a housing shown generally at34. Preferably, a plurality of fasteners connect the block32to the housing34via a plurality of apertures36,38.

The second post22is operably coupled to the movable slide16to move in the direction of the moveable slide16(in a closed direction or biased direction toward the drive shaft14and in an open direction away from the drive shaft14). Preferably, the second post22is operably connected to a second shaft40extending through an aperture42(e.g., elongated aperture) formed in the block32. The second shaft40or “slide shaft” or “moveable shaft” is operably connected to the moveable slide16.

The drive shaft14preferably extends through a locking bearing44or “cam bearing”. The locking bearing44is a one way locking bearing that spins free in one direction, and locks on drive shaft14in the other direction.

The tool head assembly10is operably arranged to allow movement of the second shaft40towards/away from the drive shaft14during operation of the tool head assembly10to accommodate variations in structural member/flange thicknesses.

The drive shaft14is rotatable about a first axis of rotation. Preferably, a predetermined tooling drive mechanism is operably coupled to the drive shaft14, and the first roller20is operably fixedly connected to the drive shaft14toward an end of the shaft outside the housing34, such that the drive shaft14and first roller20rotate together, or operably coupled to the second roller22and shaft such that the shaft and second roller22rotate together. A first gear50or “drive gear” is operably mounted on the drive shaft14. The cam12, first gear50and first roller20rotate with the drive shaft14. The drive shaft14is stationary in that the shaft14does not slide in the block32. Preferably, at least one support bearing52including bearing surfaces53is operably mounted along the drive shaft14at a predetermined location. Alternatively, the first roller20does not rotate.

The second roller22is operably connected to the slideable shaft40toward an end of the shaft outside the housing34, such that the slideable shaft40and second roller22rotate together. A second gear54, e.g., driven gear, is operably mounted on the slideable shaft40and in meshing engagement with the first gear50. Rotation of the first gear50in one direction rotates the second gear54in an opposite direction. The slideable shaft40rotates about a second axis of rotation and is also slideable along the aperture42as indicated by arrow “5”. Preferably, at least one support bearing56is operably mounted along the shaft40.

An intermediate rotary member58is operably coupled, e.g., rotatably coupled, to the second gear54by at least one member60to allow the intermediate rotary member58to rotate about an axis, preferably, about an axis that is offset from the first and second axes of rotation of the shafts14,40. An output rotary member62is operably coupled, e.g., rotatably coupled, to the intermediate rotary member58by at least one second member64to allow the output rotary member62to rotate about one of the axes of rotation. The arrangement provides for torque transfer from the drive shaft14to the slidable shaft40, and thereby from the cam12to the moveable slide16.

The tool head assembly10is operably connected to a handle shown generally at46of a crimping assembly or any other predetermined assembly. Preferably, at least one guiding member48is provided to assist the operator in moving the assembly10along the desired path during crimp processing. The tool head assembly10applies a force against the part (e.g., seal strip) to position the part relative to the the structural member (e.g., part over the flange). The partially closed gap rollers (e.g., exemplarily depicted inFIGS.9-10) apply a generally inward force to crimp the part against the side(s) of the structural member.

The tool head assembly10is arranged with the rollers20,22axis of rotations generally parallel with the longitudinal axis of the handle46. Alternatively, tool head assembly10is arranged with the rollers20,22axis of rotations generally about 90 degrees with respect to the longitudinal axis of the handle46. Alternatively, the tool head assembly10is any predetermined angle with respect to the handle46, generally about 0-180 degrees, typically about 0 to 125 degrees, preferably about 0 to 45 degrees, most preferably about 0 to 90 degrees. It is understood that the tool head assembly10rollers20,22are positioned with respect to the handle46in any predetermined orientation or angle depending on the application without departure from the scope of the present invention.

The rollers20,22can be metal or any predetermined durable material suitable to prevent damage to the part and provide crimping.

According to an aspect of the present invention, an operator engages a trigger26to open/widen the gap. The cam rotates in a first direction to push the block and open the gap, then when the tool is in place to the molding/flange, releases the trigger narrowing the gap and moving the assembly10along the predetermined path during crimp processing.

According to an aspect of the present invention, there is provided a method for mechanical variable gap crimping including providing the tool head assembly10described previously. Determining predetermined parameters, e.g., orientation(s), angle(s) and/or position feedback, crimping time, total crimping time, crimping time by predetermined area(s)/portion(s) being applied to the vehicle (e.g., curved regions, corners, generally straight paths, etc), correct speed, variable speeds, speeds based on location, pressure or force, etc. Optionally, programing predetermined parameters into a controller24. Setting/inputting predetermined parameters into a controller24(e.g., to have the drive rotate in one direction for a predetermined set time period, such as, generally about 5-60 seconds, typically 5-30 seconds, preferably 2-20 seconds, most preferably 2-10 seconds). Providing a feedback device66. Applying the predetermined part (e.g., weather strip) to the vehicle using the assembly10(e.g., vehicle flange). Compiling data that the assembly10is being and/or was used and used properly (e.g., according to the predetermined parameters). Communicating that the assembly10is being and/or was used and used properly (e.g., according to the predetermined parameters). Storing said data. Preferably, the method includes a processing capability to run reports, etc for manufacturers (OEM, weatherstrip manufacturer) for quality assurance, recall purposes, etc.

Conventional liftgate decklid tools crimp a liftgate decklid strip to a flange using crimping posts. Current tooling requires the rollers of the crimp tool to move or start in an open gap position. Once activated the rollers are required to close to a set gap to crimp/squeeze the seal onto a vehicle flange. This is done by means of a pneumatic system utilizing a pneumatic cylinder. A pneumatic system cannot reliably give feedback to verify the tool has been used for the correct amount of time. Current DC or battery tools have this capability and are used in plants currently. To use this drive, however, eliminates the ability to open and close the rollers as there is no longer a pneumatic power source to do this. To not open the rollers causes damage to the seal during the crimp process. While crimping tools have used commercially available battery drives, they have not had the ability to open and close the roller gap. These tools rely on a set gap size and the tool is rolled onto a seal under power causing damage to the seal in that area. Further, a spring loaded head mounted on a drive would need the ability to open/close for proper processing without damage, however, until the present invention, such parameters could not be met because it was not strong enough to do with electric (e.g., not powerful enough servos to open/close).

The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.