Low Cost Automation Tutorial

#177 Production technology level-up course for machine designers - 13: Vital points of component designs for insertion assembly - 1

Category : Production Technology

March 7, 2014

When the machine designers are attempting to automate (Low Cost Automation) manual operations, the proficiency of human hands are often overlooked. If this human hand proficiency is to be replicated by automated means, complex mechanisms and controls will be required leading to demerits such as: (1) increased production tact, (2) increased machine stoppages due to machine malfunctions, (3) increased investments. Vital points on component designs that eliminate the effects of human hand proficiency as much as possible on insertion assembly are explained here.

(1) Vital points of component designs lending to easier insertion assembly

The designers of the automated machinery are expected to provide guidance and leadership to provide enlightenments on the importance on component designs for easy assembly to product designers in order to increase the competitiveness of automated assembly machines. The table below shows the vital points.

Vital points on easy to assemble component designs	Example Number
Provide chamfered (rounded, tapered) edges on part insertion holes.	[Photo 1] (1)
Provide chamfers on edges on insertion holes larger than the locating errors.
Provide guiding features (chamfers, decreased diameter) on the shafts to be inserted.	[Photo 2] (2)
Design the center lines of the insertion holes to be parallel with the locating datum lines of the components receiving the insertions.
Provide considerations on the material strengths to prevent breakages of inserted parts.
Give tribological considerations (lubricity, etc.) on interfacing surfaces of the assembled parts.
Do not make the constraint length required for accurate locating longer than needed.	[Photo 1] (2)
In case of press-fits, design the interference amounts within the plastic deformation of the materials.
Design the insertion holes and shafts in shapes easy to measure the accuracies.
Design the products so the assembly can be completed by insertion in one direction from the top side.	[Photo 2]
Provide stable datum surfaces on the components receiving the insertions.
Provide insertion guides on locations and insertion holes.	[Fig.1][Photo 3]

[Photo 1] Example of insertion hole and shaft

[Fig.1] Example of the insertion guide hole

[Photo 2] Example of a product design that can be assembled by insertions all in one direction from the top

[Photo 3] Example of insertion guides provided for screw inserted assembly

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