DESC:Field of the invention:

The present invention relates to shock absorbers and more particularly, to a piston valve assembly dispenser for the shock absorber.

Background of the invention:

Normally, the shock absorber is a combination of damper and spring, in which damper performance is obtained by a set of piston valves and base valves for controlling the rebound and compression damping forces. These plate valves are to be sequenced with required quantity and direction of assembly, which play a major role on achieving required damping forces. These thin plate valves plates with a unique profile, thickness, sequence and numbers are very difficult to separate, handle and assemble as per the requirement. There are various methods available operable in manual, semi-automatic dispensing and placing, with and without andons. As the plate valves are a key part of the shock absorber, there is a need to develop an automatic dispensing and assembly of plate valves with mistake proofing method.

Accordingly, there exists need to provide a piston valve assembly dispenser for a shock absorber that overcomes the above mentioned drawbacks in the prior art.

Objects of the invention:

An object of the present invention is to provide a reliable process control of assembling of plate valves in shock absorber application.

Another object of the present invention is to provide a consistent ride comfort to the vehicles.
Summary of the invention:

Accordingly, the present invention provides a piston valve assembly dispenser (hereinafter, “the dispenser”) for a shock absorber. The dispenser comprises a machine base, a rotory table, a pallet, a first station, a second station, a pair of spider robos, an image capturing device and a control module.

The rotary table is mounted on the machine base. The first station and the second station are mounted on the rotary table. The first station includes an indexer, a plate valve slicer and fixture, and a thickness sensor mounted thereon. Specifically, the indexer is 12 positioning indexer. The plate valve slicer and fixture includes a RFID scanner and a vertical magnetic stacker mounted thereon. The vertical magnetic stacker is used for mounting plate valves to be dispensed thereon. The second station includes an indexer, a plate valve slicer and fixture, and a thickness sensor mounted thereon. Specifically, the indexer is 12 positioning indexer. Each positioning indexing passes through the thickness sensor and the image capturing device to verify the profile of the plate valves. The image capturing unit gives quality confirmation of the dispensed plate valves. The plate valve slicer and fixture includes a RFID scanner and a vertical magnetic stacker mounted thereon. The vertical magnetic stacker is used for mounting plate valves to be dispensed thereon. The pallet is used for holding the dispensed plate valves thereon. The pallet includes a barcode mounted thereon. The control unit moves the pallet to an intermediate position for loading a piston. The control module is operably connected to the pallet and programmed to a required sequence and type of components to be assembled on the shock absorber. The control module includes a processing unit, a memory unit and a driving circuitry. Specifically, the control module is a computer numerical control machine. The pair of spider robos is operably connected to the control module and adapted to pick a single plate valve every indexing as per sequence set on the control module from the first station and the second station for placing on the pallet.

Brief description of the drawings:

The objects and advantages of the present invention will become apparent when the disclosure is read in conjunction with the following figures, wherein
Figure 1 shows an exploded view of a piston valve assembly, in accordance with the present invention;

Figure 2 shows a schematic view of a shock absorber installed with the piston valve assembly, in accordance with the present invention; and

Figure 3 shows a schematic diagram of a piston valve assembly dispenser, in accordance with the present invention.

Detailed description of the invention:

The foregoing objects of the invention are accomplished, and the problems and shortcomings associated with prior art techniques and approaches are overcome by the present invention described in the present embodiments.

The present invention provides a piston valve assembly dispenser for a shock absorber. The piston valve assembly dispenser provides a consistent ride comfort by reliable process control of a plate valve assembly in the shock absorbers. The piston valve assembly dispenser eliminates mistakes related to sequence, number of plate valves and direction, and confirms operation of every part.

The present invention is illustrated with reference to the accompanying drawings, throughout which reference numbers indicate corresponding parts in the various figures. These reference numbers are shown in bracket in the following description and in the table below.
Table:
Component Name Component Number
Piston valve assembly dispenser 100
Mud wiper 1
Oil Seal 2
Rod guide 3
Du Brush 4
Valve Support 5
Piston ring 6
Piston 7
Nut 8
Nut stopper plates 10
Piston rod 12
Plate valves 13
Plate valve not return 13a
Retainer valve 14
Star washer 15
Outer tube 17
Inner tube 18
Piston valve assembly 20
Pallet 21
Spider robs 22
Plate valve slicer and fixture 23
First Station 24
Second station 25

Referring to figures 1-2, a piston assembly (not numbered) and a piston valve assembly (20) of a shock absorber (not numbered) in accordance with the present invention is shown. The piston assembly includes a piston ring (6), a piston (7) and a piston rod (12). The piston rod (12) is inserted in a central axially extending bore of a cylindrically shaped piston body (not numbered). The piston body is secured inside the shock absorber high pressure cylinder and the piston rod (12) having relatively smaller diameter is received inside the piston body by using a fastening means.

The piston valve assembly (20) includes a plurality of plate valves (13), a retainer valve (14) and a star washer (15) as shown in figure 1. The piston valve assembly (20) is secured inside the shock absorber having an elongated high pressure cylinder defining hydraulic fluid as shown in figure 2. The plurality of plate valves (13), the retainer valve (14) and the star washer (15) are disc shaped members fixedly secured over the surface of the piston rod (12) by a fixing means. The plurality of plate valves (13) are configured with a central opening/coaxial bore through which the lower end portion of the piston rod (12) extends. The piston rod (12) is allowed to move inside the high pressure cylinder with the support of a guide assembly. The reciprocal movement of the piston rod (12) and the piston (7) makes the hydraulic fluid to be transferred between the upper and lower ends of the high pressure cylinder. This action dampens relative movements of the respective vehicle and provides necessary suspension. The piston valve assembly (20) provides sufficient sealing for the fluid and selectively controls the flow of the hydraulic fluid between the upper and lower end of the fluid chamber of the high pressure cylinder during a reciprocal movement of the piston rod (12).

In an embodiment, thickness of each plate valve (13) varies from 0.15 mm to 0.2 mm and with a combination of holes and slots. The holes and slots provided on the plate valves (13) are depending up on the deflection and oil flow requirement of the shock absorber to maintain the damping force therein.

The piston assembly provides rebound damping control and the piston valve assembly (20) provides compression damping control to the shock absorber. The control method and precision is the result of ride comfort experienced by the rider. The combination and confirmation of the plurality of plate valves decides the accuracy and achieving the required damping force.
Referring now to figure 3, a piston valve assembly dispenser (hereinafter ‘the dispenser (100)’) for the shock absorber in accordance with the present invention is shown. The dispenser (100) comprises a machine base (not shown), a rotary table (not numbered), a pallet (21), a first station (24), a second station (25), a pair of spider robos (22), an image capturing device (not shown) and a control module (not numbered).

The machine base supports all the machine elements of the rotary table and the pair of spider robos (22). The pair of spider robos (22) is a high speed robos used to pick the verified valve from the stations (24, 25) for placing on the pallet (21). The pallet (21) holds the dispensed plate valves for easy handling and transport. The pallet (21) includes a barcode mounted thereon. The image capturing unit is a camera that gives quality confirmation of the dispensed plate valves.

The first station (24) and the second station (25) are mounted on the rotary table. The first station (24) includes an indexer (not shown), a plate valve slicer and fixture (23a) and a thickness sensor (not shown) mounted thereon. In an embodiment, the indexer is 12 positioning indexer. The plate valve slicer and fixture (23a) includes a vertical magnetic stacker (not shown) and a RFID scanner (not shown). The plate valves (13) to be dispensed are mounted on the vertical magnetic stacker. Each positioning indexing passes through the thickness sensor and the image capturing device to verify the profile of the plate valves (13).

The second station (25) includes an indexer (not shown), a plate valve slicer and fixture (23b) and a thickness sensor (not shown) mounted thereon. In an embodiment, the indexer is 12 positioning indexer. The plate valve slicer and fixture (23b) includes a vertical magnetic stacker (not shown) and a RFID scanner (not shown). The plate valves (13) to be dispensed are mounted on the vertical magnetic stacker. Each positioning indexing passes through the thickness sensor and the image capturing device to verify the profile of the plate valves (13).

The first station (24) and the second station (25) are the specific dispensing units for the plate valves (13). The first station (24) allows assembling of the components below the piston (7). The components below the piston (7) include for example, the plate valve (13a) and the star washer (15) as shown in figure 1. The second station (25) is used to assemble the components above the piston (7). The components above the piston (7) include for example, the plate valves (13), and the nut plates (10) as shown in figure 1. However, it is understood here that the first station (24) and the second station (25) are flexible and can perform the opposite dispensing function in other alternative embodiments of the present invention.

The control module is operably connected to the pallet and the pair of robos. The control module comprises a processing unit, a memory unit and a driving circuitry. The verification outputs are recorded and are stored in the memory unit for future reference. This helps to provide an alert if there is any wrong entry of assembly to discontinue the process and start with a fresh sequence. In an embodiment, the control module is a computer numerical control (CNC) machine. The control module is programmed to the required sequence and type of components to be assembled on the shock absorber. The order of assembly depends on the shock absorber specific configuration.

Again referring to figures 1 to 3, in an operation of the assembling of the plate valves is explained in accordance with the dispenser (100). The steps involved in dispensing of the plate valve involves loading of the plate valves in the first station (24). Thereafter, the spider robos (22) pick a single plate valve (13) every indexing as per sequence set on the control module and places on the pallet (21). When the pallet (21) is filled, the pallet (21) is moved to intermediate position by the control unit. In the intermediate position, the piston (7) is loaded. Thereafter, the plate valves are loaded into the second station (25). The spider robos (22) repeat the process as similar to the first station (24). Thereafter, the plate valves and the piston (7) are unloaded and fed to shock absorber assembly.
The method of assembling of plate valves is automated without any operator intervention. The dispenser (100) for assembling the plate valves is designed in such a way that sequence of assembly, number of plate valves, thickness, profile checking, assembly path to follow in case of any part or process defect. The system (100) is proved to multiple cycles of working and with various combinations.

Advantages of the invention:

1. The dispenser (100) eliminates mistakes related to sequence, number of plate valves and direction, and confirms operation of every part.
2. The dispenser (100) provides a consistent ride comfort by reliable process control of assembling of the plate valves in the shock absorbers.

The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, and to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the scope of the present invention.
,CLAIMS:We claim:

1. A piston valve assembly dispenser (100) for a shock absorber, the dispenser (100) comprising:
a machine base having a rotary table mounted thereon;
a first station (24) mounted on the rotary table, the first station (24) having an indexer, a plate valve slicer and fixture (23a) and a thickness sensor mounted thereon, the plate valve slicer and fixture (23a) having a RFID scanner, and a vertical magnetic stacker for mounting the plate valves to be dispensed thereon;
a second station (25) mounted on the rotary table, the second station (25) having an indexer, a plate valve slicer and fixture (23b) and a thickness sensor mounted thereon, the plate valve slicer and fixture (23b) having a RFID scanner, and a vertical magnetic stacker for mounting the plate valves to be dispensed thereon;
a pallet (21) for holding the dispensed plate valves thereon, the pallet (21) having a barcode mounted thereon;
an image capturing unit for giving quality confirmation of the dispensed plate valves;
a control module operably connected to the pallet and programmed to a required sequence and type of components to be assembled on the shock absorber, the control module having a processing unit, a memory unit and a driving circuitry;
a pair of spider robos (22) operably connected to the control module and adapted to pick a single plate valve (13) every indexing as per sequence set on the control module from the first station (24) and the second station (25) for placing on the pallet (21).

2. The dispenser (100) as claimed in claim 1, wherein the control module is a computer numerical control machine.

3. The dispenser (100) as claimed in claim 1, wherein the indexer is 12 positioning indexer and each positioning indexing passes through the thickness sensor and the image capturing device to verify the profile of the plate valves (13).

4. The dispenser (100) as claimed in claim 1, wherein the control unit moves the pallet (21) to an intermediate position for loading a piston (7).