Optimized Flow Drill Screw Installation for Thick Materials
Here’s PatSnap Eureka !
Summary
Problems
Existing methods for installing flow drill screws (FDS) in substrates, particularly thicker materials, often require excessive torque, which can lead to screw failure or substrate fracture, and typically necessitate additional materials or specialty fasteners.
Innovation solutions
A method for operating an automatic tool to install FDS in substrates, involving a two-stage process: an initial high-speed, high-force setting to penetrate the substrate, followed by a lower-speed, lower-force setting once specific trigger conditions are met, such as a depth gradient or axial feed distance, to ensure successful thread formation and tightening without excessive torque.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If high RPM and high axial force are used to penetrate thick substrates, then penetration capability is improved, but installation torque increases excessively causing screw fracture or substrate damage
Why choose this principle:
The installation process is divided into three distinct phases: penetration phase (high RPM/high force), transition phase (intermediate RPM/intermediate force), and thread formation phase (low RPM/low force). This segmentation allows the system to optimize parameters for each specific stage, achieving penetration capability while controlling final torque to prevent screw fracture or substrate damage.
Principle concept:
If high RPM and high axial force are used to penetrate thick substrates, then penetration capability is improved, but installation torque increases excessively causing screw fracture or substrate damage
Why choose this principle:
The system dynamically adjusts RPM and axial force based on real-time penetration depth and substrate resistance. The controller continuously monitors installation progress and modifies operational parameters mid-process, transitioning from high-power penetration mode to low-power thread formation mode, thereby maintaining penetration capability while preventing excessive final torque.
Application Domain
Data Source
AI summary:
A method for operating an automatic tool to install FDS in substrates, involving a two-stage process: an initial high-speed, high-force setting to penetrate the substrate, followed by a lower-speed, lower-force setting once specific trigger conditions are met, such as a depth gradient or axial feed distance, to ensure successful thread formation and tightening without excessive torque.
Abstract
A method includes operating an automatic tool at a first setting to drive a flow drill screw (FDS) into a substrate. The first setting is configured to rotate the FDS at a first rotational speed and apply a first axial feed force. The first setting is configured to cause flow of the substrate to permit the FDS to penetrate the substrate. The method includes detecting a predetermined first trigger condition including at least one of a depth gradient and a depth and switching the tool from the first setting to a second setting in response to a predetermined second trigger condition including at least one of a predetermined axial feed distance after detecting the first trigger condition and a predetermined time delay after detecting the first trigger condition. The second setting is configured to rotate the FDS at a lower rotational speed and apply a lower axial feed force.