Manufacturing method of a jointed structure

Abstract

To provide a manufacturing method of a joint structure in which a plurality of plates are joined without welding and without using a separate member from the plurality of plates.SOLUTION: A manufacturing method of a joint structure comprises steps of: preparing a plurality of metal plates including a first plate and a second plate; overlapping the plurality of plates to form a laminated region where each of the first plate and the second plate becomes an outermost layer; radially making a cut penetrating the first plate at the laminated region to form a plurality of first pieces partitioned from each other; bending the plurality of first pieces in a first direction from the first plate to the second plate to form a first through hole in the first plate coaxially with a second through hole in the second plate; and folding back the plurality of first pieces into an outer peripheral side of the first through hole to sandwich the second plate between the first piece and the first plate.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a joined structure in which a plurality of plate materials are joined.

Background Art

[0002] Patent Document 1 discloses spot welding. Spot welding sandwiches a plurality of panels with a pair of electrodes facing each other and energizes between the pair of electrodes to weld the plurality of panels.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In spot welding, for example, when welding different metal plate materials, an intermetallic compound is formed at the welded portion. However, when an intermetallic compound is formed, the welded portion becomes brittle and the joining strength decreases. As a means for joining a plurality of plate materials without welding, for example, caulking using a rivet can be mentioned. However, a separate member is required from the plurality of plate materials, and the number of parts increases.

[0005] One object of the present invention is to provide a method for manufacturing a joined structure in which a plurality of plate materials are joined without welding and without using a separate member from the plurality of plate materials.

Means for Solving the Problems

[0006] A method for manufacturing a joined structure according to one aspect of the present invention includes: a step of preparing a plurality of plate materials including a first plate material and a second plate material made of metal; a step of overlapping the plurality of plate materials with each other to provide a laminated region having each of the first plate material and the second plate material on the outermost layer; The process of forming a plurality of first pieces that are partitioned from each other by making radial cuts that penetrate the first plate material in the laminated region, The process of forming a first through-hole in the first plate material that is coaxial with the second through-hole in the second plate material by bending the plurality of first pieces in a first direction from the first plate material toward the second plate material, The process includes folding the plurality of first pieces back toward the outer circumference of the first through-hole, thereby sandwiching the second plate material between the first pieces and the first plate material, The second through-hole satisfies either requirement (A) or requirement (B) below. (A) In the step of forming the plurality of first pieces, radial cuts are made through the second plate material together with the first plate material to form a plurality of partitioned second pieces, and in the step of forming the first through hole, the plurality of second pieces are bent in the first direction together with the plurality of first pieces to form the first through hole. (B) Provided in advance on the second plate material during the preparation process. [Effects of the Invention]

[0007] The above-described method for manufacturing a joined structure allows for the production of a joined structure in which multiple plates are joined together by multiple first pieces formed from a part of the first plate and the first plate, by performing the above-described steps. In other words, the above-described method for manufacturing a joined structure allows for the joining of multiple plates without welding them to each other. Therefore, even if the multiple plates are made of different metals, the above-described method for manufacturing a joined structure can join multiple plates without forming weak points such as intermetallic compounds. Furthermore, the above-described method for manufacturing a joined structure allows for the joining of multiple plates without using any separate components from the multiple plates. Therefore, since the number of parts does not increase, the above-described method for manufacturing a joined structure can suppress cost increases. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is an explanatory diagram illustrating steps A to D of the manufacturing method of a joined structure according to an embodiment. [Figure 2]Figure 2 is an explanatory diagram illustrating step E of the manufacturing method of the joined structure according to the embodiment. [Figure 3] Figure 3 is a cross-sectional view showing a jointed structure manufactured by the method for manufacturing a jointed structure according to the embodiment. [Figure 4] Figure 4 is an explanatory diagram illustrating a plurality of first pieces formed in step C of the manufacturing method of a joined structure according to the embodiment. [Figure 5] Figure 5 is an explanatory diagram illustrating a method for manufacturing a modified joint structure. [Modes for carrying out the invention]

[0009] 《Embodiment》 [Method for manufacturing a jointed structure] A method for manufacturing a joined structure according to the embodiment will be described below with reference to Figures 1 to 4. In Figures 1 and 2, hatching of the cross-sections of the multiple plate materials 10 is omitted for the sake of clarity. The method for manufacturing a joined structure according to the embodiment involves joining multiple plate materials 10 to each other. The method for manufacturing a joined structure according to the embodiment comprises a step A of preparing multiple plate materials 10 and a step B of creating a laminated region by overlapping the multiple plate materials 10. One of the features of the method for manufacturing a joined structure according to the embodiment is that it further comprises specific steps C to E. In the following description, the side of the second plate material 12 facing the first plate material 11 is referred to as the upper side, and the side of the first plate material 11 facing the second plate material 12 is referred to as the lower side.

[0010] [Process A] The multiple sheet materials 10 prepared in process A may all have the same constituent materials, or at least one sheet material may have different constituent materials from the remaining sheet materials. Having the same constituent materials means that the types of constituent elements are the same and the content of those elements is the same. Having different constituent materials means that the types of constituent elements are different, or that the types of constituent elements are the same and the content of those elements is different.

[0011] In this embodiment, the plurality of plates 10 consist of two plates: a first plate 11 and a second plate 12. The constituent material of the first plate 11 is metal. Examples of metals include aluminum, aluminum alloy, iron, and iron alloy. In this embodiment, the first plate 11 is an iron plate. The constituent material of the second plate 12 is metal in this embodiment. Examples of metals are the same as those for the first plate 11. In this embodiment, the second plate 12 is an aluminum plate. Unlike this embodiment, the constituent material of the second plate 12 may be a non-metallic material. Examples of non-metallic materials include resin or rubber. Unlike this embodiment, the plurality of plates 10 may consist of three or more plates.

[0012] [Process B] In step B, as shown in the left diagram of Figure 1, multiple plates 10 are stacked so that the first plate 11 and the second plate 12 are each located in the outermost layer of the stacking region. The first plate 11 is placed facing the first tool 1 (described later), and the second plate 12 is placed facing the second tool 2 (described later). Here, the first plate 11 is placed on top of the second plate 12. Unlike this embodiment, if there are three or more plates 10, plates other than the first plate 11 and the second plate 12 are placed between the first plate 11 and the second plate 12.

[0013] [Process C] Step C involves making radial cuts through the first plate material 11 in the laminated region, as shown in the center view of Figure 1. Figure 4 shows an example of the cuts 11a formed in the first plate material 11. Figure 4 shows the cuts 11a formed in the first plate material 11 as viewed from the first tool 1 towards the second tool 2. By forming the cuts 11a, multiple first pieces 11b are formed in the first plate material 11. The number of first pieces 11b is not particularly limited as long as there are three or more. In this embodiment, four first pieces 11b are formed. The multiple first pieces 11b are separated from each other by the cuts 11a.

[0014] In this embodiment, radial cuts that penetrate the second plate 12 are also made in the second plate 12 together with the first plate 11. Although not shown, the cuts formed in the second plate 12 are the same as the cuts in the first plate 11. For example, if a cut 11a shown in FIG. 4 is formed in the first plate 11, a cut similar to the cut 11a shown in FIG. 4 is also formed in the second plate 12. The cuts in the second plate 12 form a plurality of second pieces 12b in the second plate 12. The plurality of second plate pieces are partitioned from each other.

[0015] Unlike this embodiment, when there are three or more of the plurality of plates 10, by making radial cuts that penetrate each of the plates other than the first plate 11 together with the first plate 11, a plurality of pieces partitioned from each other are formed. The cuts formed in the plates other than the first plate 11 are the same as the cuts in the first plate 11. The plates other than the first plate 11 include the second plate 12.

[0016] Steps C to step E described later can be performed using, for example, the first tool 1 and the second tool 2. The first tool 1 and the second tool 2 are provided at the tip of one robot arm not shown. The first tool 1 and the second tool 2 are moved to desired positions by the robot arm. The first tool 1 and the second tool 2 face each other. The first tool 1 and the second tool 2 move forward and backward by a drive mechanism not shown. Forward movement means that the first tool 1 and the second tool 2 move in a direction approaching each other. Backward movement means that the first tool 1 and the second tool 2 move in a direction away from each other.

[0017] Process C can be performed using the first tool 1. The shape of the first tool 1 is not particularly limited as long as it can form a cut without shaving the first plate material 11 as much as possible. The first tool 1 of the present embodiment has a base portion 1a and a tip portion 1b. The shape of the base portion 1a is cylindrical or prismatic. The base portion 1a and the tip portion 1b are integrally formed. The tip portion 1b has three or more cutting edges. The three or more cutting edges are provided radially from the center of the tip portion 1b toward the outer periphery. Since the number of cutting edges is three or more and they are provided radially, the three or more first pieces 11b formed can be bent in a later-described process D. When the shape of the base portion 1a is prismatic, it is preferable that the cutting edges are provided so as to extend radially in the diagonal direction. In this case, the first piece 11b and the second piece 12b can be easily bent at the base portion 1a. The larger the number of cutting edges, the easier it is to bend each first piece 11b. An example of the number of cutting edges is three, four, five, or six. Of course, the number of cutting edges may be seven or more. Each of the three or more cutting edges extends linearly from the center of the tip of the first tool 1 toward the outer periphery. The cut 11a shown in FIG. 4 is an example formed in the first plate material 11 using the first tool 1 provided at the tip portion 1b such that four cutting edges extend radially from the center of the tip toward the outer periphery. The tip portion 1b is preferably tapered. When the tip is tapered, it is easy to form a cut and it is also easy to bend a plurality of first pieces 11b in a later-described process D.

[0018] From the initial position of the first tool 1 shown in the left diagram of FIG. 1, the first tool 1 is advanced as shown in the central diagram of FIG. 1. The cutting edge of the tip portion 1b of the advanced first tool 1 contacts the first plate material 11. The first tool 1 is advanced to a position where it penetrates the first plate material 11 over the entire length of the cutting edge. When it is advanced to that position, a radial cut 11a that penetrates the first plate material 11, for example, as shown in FIG. 4, is formed in the first plate material 11. The first tool 1 is advanced to a position where it penetrates the second plate material 12 over the entire length of the cutting edge. If the first tool 1 is advanced to that position, although not shown, a cut that penetrates the second plate material 12 is formed in the second plate material 12. This cut is, for example, the same as the cut 11a shown in FIG. 4. In order to make it easier to form the cut, the first tool 1 may be vibrated.

[0019] When forming a cut in the first plate material 11, it is preferable to use the first support mechanism 4. The first support mechanism 4 supports the multiple plate materials 10 from the side opposite to the first tool 1. The first support mechanism 4 of this embodiment has a first leg portion 4a and a first drive mechanism 4b. The first leg portion 4a supports the lower surface of the second plate material 12. The first leg portion 4a is arranged to surround the outer circumference of the second tool 2. A gap is provided between the first leg portion 4a and the second tool 2. The shape of the first leg portion 4a is cylindrical or rectangular. Figure 1 shows a cross-section of the first leg portion 4a. In Figure 1, for the sake of explanation, the hatching of the cross-section of the first leg portion 4a is omitted. The end face of the first leg portion 4a is flat. The shape of the end face of the first leg portion 4a is circular or rectangular. The first drive mechanism 4b raises and lowers the first leg portion 4a. The type of the first drive mechanism 4b is not particularly limited. The first drive mechanism 4b may be a spring cylinder or an air cylinder. The first drive mechanism 4b moves the first leg portion 4a to a position where its end face contacts the lower surface of the second plate material 12. The support provided by the first leg portion 4a makes it easier for the first tool 1 to make a cut in the first plate material 11 in step C, and makes it easier for the first tool 1 to bend the first piece 11b in step D, which will be described later.

[0020] [Process D] Step D involves bending a plurality of first pieces 11b in a first direction from the first plate material 11 toward the second plate material 12, as shown in the right-hand diagram of Figure 1. The bending of the plurality of first pieces 11b forms a first through hole 11c in the first plate material 11.

[0021] In this embodiment, multiple second pieces 12b are bent in the first direction along with multiple first pieces 11b. The bending of the multiple second pieces 12b forms a second through hole 12c in the second plate material 12. The first through hole 11c and the second through hole 12c in the second plate material 12 are coaxial.

[0022] Unlike this embodiment, if there are three or more plates 10, multiple pieces of each plate other than the first plate 11 are bent in the first direction along with the multiple first pieces 11b. Through holes are formed in each of the plates other than the first plate 11 by bending the multiple pieces of each plate other than the first plate 11. Each through hole and the first through hole 11c are coaxial.

[0023] Process D can be performed using the first tool 1 described above. The first tool 1, advanced in process C, can be used to bend multiple first pieces 11b in the right-hand diagram of Figure 1, in conjunction with the formation of the cut in the first plate material 11. The bending of the multiple first pieces 11b is performed using the base 1a of the first tool 1. In addition, multiple second pieces 12b can be bent in conjunction with the formation of the cut in the second plate material 12. The bending of the multiple second pieces 12b is performed by bending the multiple first pieces 11b. The second tool 2 is kept in a position where it does not come into contact with the advanced first tool 1. Because the tip 1b of the first tool 1 is tapered, multiple first pieces 11b are easily bent in the first direction as the first tool 1 is advanced. As the first pieces 11b are bent, multiple second pieces 12b also bend in the first direction.

[0024] As the first tool 1 advances, multiple first pieces 11b and multiple second pieces 12b are formed along the first direction, as shown in the right-hand diagram of Figure 1. The inner edges of the multiple first pieces 11b along the first direction form the first through hole 11c. The inner dimensions of the first through hole 11c are substantially the same as the outer dimensions of the base 1a of the first tool 1. The inner edges of the multiple second pieces 12b along the first direction form the second through hole 12c. The inner dimensions of the second through hole 12c are substantially the same as the outer dimensions of the multiple first pieces 11b. The inner dimensions of the lower end of each through hole increase in stages by the thickness of each of the multiple plate materials 10.

[0025] [Process E] Step E involves folding multiple first pieces 11b towards the outer circumference of the first through hole 11c. By plastically deforming the multiple first pieces 11b so that they are folded back, the second plate material 12 is sandwiched between each first piece 11b and the first plate material 11.

[0026] In this embodiment, multiple second pieces 12b are folded back toward the outer periphery along with multiple first pieces 11b. By folding back the multiple second pieces 12b, the multiple second pieces 12b and the second plate material 12 are sandwiched between each of the multiple first pieces 11b and the first plate material 11.

[0027] Unlike this embodiment, when there are three or more plates 10, the edges of the plates 10 are folded back toward the outer periphery. By folding back the edges of the plates 10, edges of plates other than the first plate 11 and plates other than the first plate 11 are sandwiched between the multiple first pieces 11b and the first plate 11.

[0028] Process E can be carried out by advancing the second tool 2. The shape of the tip surface 2a of the second tool 2 is not particularly limited as long as it is a shape that can fold each first piece 11b towards the outer circumference. For example, if the tip surface 2a of the second tool 2 is inclined downward from the center toward the outer circumference, it is easier to fold each first piece 11b toward the outer circumference.

[0029] As shown in the left, center, and right figures of Figure 2, the second tool 2 is advanced. The tip surface 2a of the advanced second tool 2 comes into contact with the multiple first pieces 11b. The second tool 2 is advanced so that the multiple second pieces 12b come into contact with the lower surface of the second plate material 12. This advancement creates a joined structure in which the multiple second pieces 12b and the second plate material 12 are sandwiched between each of the multiple first pieces 11b and the first plate material 11, as shown in Figure 3. Therefore, the manufacturing method of the joined structure of this embodiment allows multiple plate materials 10 to be joined without welding and without using a separate component from the multiple plate materials 10. The manufacturing method of the joined structure of this embodiment does not increase the number of parts, thus suppressing cost increases. Moreover, since the above-mentioned joined structure can be manufactured by replacing the tip of an existing robot arm with the first tool 1 and the second tool 2, capital investment can be suppressed. In particular, a robot arm equipped with a welding gun can be suitably used as an existing robot arm. The welding gun is equipped with a pair of welding electrodes that face each other and are brought close or separated from each other. By replacing this pair of welding electrodes with a first tool 1 and a second tool 2, the manufacturing method of the joined structure according to this embodiment can be carried out. In other words, equipment costs can be saved by utilizing existing equipment.

[0030] When folding back the multiple first pieces 11b, it is preferable to use the second support mechanism 5 shown in Figures 1 and 2. The second support mechanism 5 supports the multiple plate materials 10 from the side opposite to the second tool 2. The second support of this embodiment Mechanism 5 It has a second leg portion 5a and a second drive mechanism 5b similar to the first leg portion 4a and first drive mechanism 4b of the first support mechanism 4. The second drive mechanism 5b moves the second leg portion 5a to a position where its end face contacts the upper surface of the first plate material 11. The support provided by the second leg portion 5a makes it easier for the second tool 2 to fold back the multiple first pieces 11b towards the outer circumference in process E.

[0031] When forming multiple joints, steps C through E are repeated.

[0032] 《Example 1》 In Modification 1, as shown in Figure 5, steps C and D may be performed with the first tool 1, and step E may be performed with the third tool 3. The first tool 1 and the third tool 3 are provided at the tips of different robot arms. The first tool 1 is as described in the embodiment. The tip of the robot arm on which the first tool 1 is provided does not have the second tool 2 described above with reference to Figure 2. The third tool 3 comprises a first member 3a and a second member 3b that sandwich a plurality of plate materials 10 from both sides in the stacking direction. The tip surface of the first member 3a is flat. The tip surface of the second member 3b is the same as the tip surface 2a of the second tool 2 described above with reference to Figure 2. The tip surfaces of the first member 3a and the second member 3b are opposite to each other. In step E, the first member 3a is advanced so that its tip surface contacts the upper surface of the first plate material 11, and then the second member 3b is advanced. In steps C and D of this example, it is preferable to use the first support mechanism 4, as in the embodiment. The first support mechanism 4 may be provided on the robot arm, or on a jig that fixes multiple stacked plate materials 10. In addition, in processes C and D, a fixed support base may be used instead of the first support mechanism 4. In this example, the second support mechanism 5 shown in Figures 1 and 2 can be made unnecessary.

[0033] 《Modified Example 2》 In Modification 1, at least one of the multiple plate materials prepared in step A, other than the first plate material, may have a through hole provided in advance. For example, the multiple plate materials may consist of two plate materials, a first plate material and a second plate material, and the second plate material may have a second through hole provided in advance. In this case, in step B, a laminated region is created in which the first plate material is stacked on top of the second plate material so that the second through hole is covered by the first plate material. In step C, radial cuts are made through the first plate material at the location in the first plate material that overlaps with the second through hole. Steps D and E are as described in the embodiment. In this example, the peripheral edge of the second through hole of the second plate material is sandwiched between the first piece and the first plate material.

[0034] The present invention is not limited to these examples, but is intended to include all modifications within the meaning and scope equivalent to the claims as shown by the claims. [Explanation of Symbols]

[0035] 10 plural plates 11 First sheet material, 11a Cutting, 11b First piece, 11c First through hole 12 Second plate, 12b Second sheet, 12c Second through hole 1. First tool, 1a. Base, 1b. Tip 2. Second tool, 2a tip face 3. Third tool, 3a. First component, 3b. Second component 4. First support mechanism, 4a. First foot, 4b. First driving mechanism 5 Second support mechanism, 5a Second foot, 5b Second driving mechanism

Claims

[Claim 1] Step A involves preparing multiple sheet materials, including a first sheet material and a second sheet material made of metal. Step B involves stacking the plurality of plate materials on top of each other to form a laminated region having the first plate material and the second plate material as the outermost layer, Step C involves making radial cuts through the first plate material in the laminated region to form a plurality of first pieces that are partitioned from each other, Step D involves bending the plurality of first pieces in a first direction from the first plate material toward the second plate material to form a first through-hole in the first plate material that is coaxial with the second through-hole in the second plate material, The process includes step E, which involves folding the plurality of first pieces back toward the outer circumference of the first through-hole, thereby sandwiching the second plate material between the first pieces and the first plate material. Each of the aforementioned steps C, D, and E is performed with the plurality of plate materials sandwiched from both sides in the stacking direction by the first support mechanism and the second support mechanism. The first support mechanism has a cylindrical first leg portion that surrounds the outer circumference of the second tool that folds back the plurality of first pieces, The second support mechanism has a cylindrical second leg portion that surrounds the outer circumference of the first tool used to make the cut, The second through-hole satisfies either requirement (A) or requirement (B) below: A method for manufacturing a bonded structure. (A) In step C, radial cuts are made through the second plate material together with the first plate material to form a plurality of partitioned second pieces, and in step D, the plurality of second pieces are bent in the first direction together with the plurality of first pieces to form the second pieces. (B) Provided in advance on the second plate material in step A.

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