Asymmetric Welding Auxiliary Element for Self-Alignment
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Solution Overview
Problem
Existing methods for thermal joining of components made from different metal materials are labor-intensive and require precise positioning of auxiliary elements, leading to high manufacturing effort and reduced process reliability.
Innovation Solution
A cylindrical auxiliary element with symmetrical W-shaped end faces and an annular groove design, allowing for simplified alignment and positioning, facilitating a cold-forged manufacturing process that accommodates tolerances and reduces handling effort, enabling efficient thermal joining of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If auxiliary elements are pressed into the first component with exact positioning and alignment, then welding precision is improved, but manufacturing effort and handling time increase significantly
Solution Approach 1:
The auxiliary element features an asymmetric design with a flat end face for pressing and a domed end face for welding. This asymmetry enables automatic orientation during the pressing process, eliminating the need for precise alignment while maintaining welding precision. The flat end face contacts the component assembly during pressing, while the domed end face protrudes to form the welding head, ensuring correct positioning without additional handling effort.
Solution Approach 2:
The auxiliary element's geometry enables self-positioning and self-alignment during the pressing process. The asymmetric shape with flat and domed end faces causes the element to automatically orient itself correctly when pressed into the component assembly, eliminating the need for external alignment mechanisms or precise positioning operations by operators or machinery.
2Manufacturing precision
If auxiliary elements require exact alignment during pressing, then welding quality is improved, but process reliability decreases due to higher demands on positioning accuracy
Solution Approach 1:
The asymmetric geometry with flat and domed end faces creates a self-aligning feature that tolerates variations in positioning. The element naturally orients itself during pressing, reducing sensitivity to positioning errors and eliminating defects caused by misalignment, thereby improving process reliability while maintaining welding quality.
Solution Approach 2:
The design anticipates potential positioning errors by incorporating a geometric feature (asymmetric end faces) that compensates for misalignment. This prevents alignment-related defects before they occur, ensuring reliable welding results even when positioning accuracy varies within normal tolerances.
3Manufacturing precision
If the auxiliary element has asymmetric end faces for precise positioning, then positioning accuracy is improved, but device complexity increases
Solution Approach 1:
The auxiliary element employs a simple asymmetric geometry with flat and domed end faces that provides self-positioning capability. This minimal asymmetric design achieves positioning accuracy without complex features, maintaining simplicity in manufacturing while enabling automatic orientation during the pressing process.
4Manufacturing precision
If manual handling and positioning of auxiliary elements is performed, then positioning precision can be achieved, but handling effort and time consumption increase
Solution Approach 1:
The auxiliary element's asymmetric design with flat and domed end faces enables self-positioning during the pressing operation. The element automatically orients itself correctly without requiring manual alignment or positioning operations, eliminating time-consuming handling steps while ensuring accurate positioning for welding.
Solution Approach 2:
The asymmetric geometry provides automatic orientation during pressing, eliminating the need for manual positioning operations. The flat end face contacts the component assembly first, and the domed end face naturally protrudes to the correct position, reducing handling time while maintaining positioning precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly reduces handling effort and increases process reliability by eliminating the need for precise alignment, accommodating manufacturing tolerances, and ensuring correct positioning of the auxiliary element, resulting in a stable and efficient welding process.
Implementation Method 1
The auxiliary element is introduced mechanically into the first component, which cannot be welded or is difficult to weld, preferably pressed or stamped
Implementation Method 2
thermal joining, preferably welding, of the two components via contact with the auxiliary element is now possible
Data Source
Figure 1A~2B
Figure 3A~3F
Figure 4~5
AI summary
This application relates to a method for joining at least two components (1, 14), wherein the components (1) are thermally joined to one another by means of an auxiliary element (2), comprising the following process steps: inserting a first component (1) and an auxiliary element (2) into a joining device (3) and clamping the first component (1) between a die (4) and a hold-down device (5) of the joining device (3), placing the auxiliary element (2) onto the end face (7) of the first component (1) facing the hold-down device (5), pressing the auxiliary element (2) into the first component (1) by means of a punch (6) that is axially displaceable towards the die (4), wherein the auxiliary element (2) is deformed during the pressing-in process in such a way as tothat a portion of the end face (8) of the auxiliary element (2) facing the punch (6) is displaced radially outwards, and a further portion of the end face (8) of the auxiliary element (2) forms a welding boss (9) projecting beyond the end face (8) towards the punch (6); placement of a second component onto the end face (7) of the first component (1), preferably with intermediate application of an adhesive material (15), wherein the auxiliary element (2) contacts the second component with its surface (9) projecting beyond the contour of the end face (7) of the first component (1); and thermal joining, preferably welding, of the components (1) to each other via the interposed auxiliary element (2), wherein one welding electrode is in contact with the first component (1) and another welding electrode is in contact with the second component. A corresponding device and auxiliary element are also defined.