Adaptive Bumper Sensor Holder Welding Fixture
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Solution Overview
Problem
Existing assembly devices for attaching sensor holders to large, three-dimensional plastic bumpers in the automotive industry face challenges in achieving short cycle times due to variations in bumper dimensions and sensor holder arrangements, as they are not adaptable to different vehicle types and dimensions, and lack clear mechanisms for applying necessary welding pressure.
Innovation Solution
The assembly device features a processing unit with freely radiating diode lasers and hold-down devices that include grippers and transparent hold-down elements, allowing for simultaneous welding of multiple sensor holders on a bumper with adjustable spacers and a frame that can adapt to various bumper shapes and dimensions, ensuring proper alignment and contact pressure for welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed assembly device is used for welding sensor holders to bumpers, then the welding process is simple and reliable, but the device cannot adapt to different bumper dimensions and sensor holder arrangements across various vehicle types
Solution Approach 1:
The assembly device incorporates movable and adjustable components including spacers that can be positioned at different distances from the center line, and hold-down devices that can be adjusted to accommodate various sensor holder arrangements. This dynamic adjustability allows the same device to adapt to different bumper dimensions and sensor configurations across multiple vehicle types without requiring multiple dedicated fixtures.
Solution Approach 2:
The device is designed as a universal assembly system that can handle multiple vehicle types and bumper configurations through standardized adjustable components. The spacers and hold-down devices can be repositioned and reconfigured to accommodate different sensor holder positions and bumper geometries, making a single device capable of performing multiple welding tasks that would otherwise require separate specialized fixtures.
2Productivity
If multiple sensor holders are welded simultaneously to reduce cycle time, then productivity increases, but the device must accommodate varying distances between sensor holders on different vehicle types
Solution Approach 1:
The assembly device divides the welding task into multiple independent welding stations, each equipped with its own laser welding unit and hold-down device. This segmentation allows each station to operate independently and simultaneously weld different sensor holders at different positions on the bumper, maintaining adaptability to various sensor arrangements while achieving high productivity through parallel processing.
Solution Approach 2:
The spacers and hold-down devices are designed with adjustable positioning capabilities that allow them to be dynamically reconfigured for different sensor holder distances and positions. This dynamic adjustability enables the device to maintain optimal welding parameters for each sensor holder location while welding multiple components simultaneously, thus preserving both productivity and adaptability.
3Force
If a simple hold-down mechanism is used, then the device structure is simple, but insufficient contact pressure cannot be applied to ensure proper welding of sensor holders to the bumper
Solution Approach 1:
The hold-down devices incorporate pneumatic or hydraulic pressure systems that can generate and apply controlled contact pressure to the sensor holders during welding. These pressure systems provide sufficient force to ensure proper welding while maintaining a relatively simple device structure through the use of standardized pneumatic/hydraulic components rather than complex mechanical force application mechanisms.
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
This solution enables efficient simultaneous welding of multiple sensor holders on bumpers of different dimensions, ensuring precise alignment and consistent contact pressure, thereby reducing cycle times and accommodating various vehicle-specific configurations.
Implementation Method 1
a laser directed at the joining area
Implementation Method 2
A laser welding gun with a diode laser is described here. The laser radiation leaves the laser welding gun through a transparent opening in the housing
Implementation Method 3
The sensor holder has a laser-transparent joining area with which it rests on the bumper
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a mounting device for the simultaneous welding of a plurality of sensor holders (2) along a horizontal line (1.3) of a bumper (1). Said mounting device can be advantageously adapted to different dimensions of bumpers (1) and comprises per sensor holder (2) one or two freely radiating diode lasers (6) and a holding-down element (8) arranged downstream thereof in the direction of emission, which comprises a gripper (8.1) for receiving the sensor holder (2) and a holding-down element (8.2) for introducing a contact pressure, said holding-down element being permeable in partial areas for the laser radiation of the diode laser (6).