Adaptive SPR Tool Adjusts Penetration Depth for Tolerances
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Solution Overview
Problem
Self-pierce riveting systems face variability in joining workpieces due to manufacturing tolerances, leading to inconsistent joint strengths as some rivets over-penetrate or under-penetrate, resulting from the same installation tool being used for rivets of varying lengths and workpieces of different thicknesses.
Innovation Solution
An adaptive self-pierce rivet installation tool system that adjusts insertion parameters based on stack-up parameters, including workpiece thickness, rivet length, and material properties, using sensors and a microprocessor to ensure optimal penetration and interlocking, with the ability to collect and store data for real-time feedback and adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the same punch displacement is used for all SPRs, then the installation process is simple and fast, but the penetration depth varies due to manufacturing tolerances in SPR length and workpiece thickness
Solution Approach 1:
The system dynamically adjusts the punch displacement for each SPR installation based on real-time measurements of SPR length and workpiece thickness. The controller modifies the insertion parameters adaptively, transitioning from a static fixed-displacement approach to a dynamic variable-displacement approach that accounts for manufacturing tolerances and ensures consistent penetration depth.
Solution Approach 2:
The system implements feedback by measuring the actual SPR length and workpiece thickness using sensors, then using this information to adjust the punch displacement. The controller receives measurement data and modifies the insertion parameters accordingly, creating a closed-loop control system that ensures consistent penetration despite variations in component dimensions.
2Manufacturing precision
If adaptive adjustment of insertion parameters is implemented, then penetration depth consistency is improved, but the device complexity increases due to additional sensors and control systems
Solution Approach 1:
The system performs self-measurement and self-adjustment by using sensors to automatically measure SPR length and workpiece thickness, then automatically adjusting the punch displacement through the controller. This eliminates the need for manual measurement and parameter setting, reducing operational complexity while maintaining high precision.
Solution Approach 2:
The system replaces manual measurement and calculation processes with automated sensors and a controller that electronically determine the optimal punch displacement. This substitution of mechanical/manual operations with electronic automation reduces the complexity of manual procedures while achieving precise control.
Data Source
AI summary
A method of installing a self-piercing rivet (SPR) is provided that includes providing an SPR installation tool with stack-up parameters prior to, during, and/or after insertion of the SPR into at least two adjacent workpieces, adjusting at least one insertion parameter of the SPR installation tool based on the stack-up parameters, and adaptively installing the SPR into the adjacent workpieces.