Clinch Nut Joining for AHSS With Contained Laser Heating
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Solution Overview
Problem
Existing methods for securing clinch nuts to advanced high strength steel sheets are inefficient and pose safety risks due to the need for laser heating, which requires light-safe processing stations to prevent operator exposure to scattered radiation.
Innovation Solution
A joining assembly with a base, indexing member, and laser assembly that moves between heating and joining positions, ensuring safe operation by containing the laser beam within a light-safe chamber and using a detector assembly to prevent exposure, while allowing for the secure attachment of clinch nuts to the steel sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If laser heating is used to secure clinch nuts to advanced high strength steel sheets, then the mechanical joining process is improved, but operator safety is compromised due to scattered radiation exposure
Solution Approach 1:
The processing station is divided into a light-safe zone (enclosure) and a non-light-safe zone. The laser assembly and workpiece are contained within the light-safe enclosure, separating the harmful laser radiation from the operator area while maintaining efficient mechanical joining processes within the safe zone.
Solution Approach 2:
A light-safe enclosure acts as an intermediary barrier between the laser beam and the operator. This enclosure contains the scattered radiation while allowing the laser heating process to proceed efficiently, thus protecting the operator without interfering with the mechanical joining process.
2Object-affected harmful factors
If a light-safe enclosure is implemented to contain laser radiation, then operator safety is improved, but processing station complexity increases
Solution Approach 1:
The laser assembly is extracted and mounted on a movable carriage that travels along rails within the light-safe enclosure. This separation allows the laser unit to be positioned independently and moved to different work locations, reducing the need for a fully enclosed complex structure while maintaining radiation containment.
Solution Approach 2:
The laser assembly is made dynamic through the movable carriage system, allowing it to translate along the rails to different workpiece locations. This dynamic positioning reduces the structural complexity of the enclosure compared to a fully fixed and enclosed system, while still maintaining light-safe containment.
3Adaptability or versatility
If the laser assembly is made movable on a carriage, then flexibility and adaptability are improved, but device complexity increases
Solution Approach 1:
The movable carriage system serves multiple functions: it positions the laser assembly at different work locations, provides a stable mounting platform, and integrates with the enclosure structure. This multi-functionality reduces the need for separate positioning mechanisms, thereby limiting the increase in overall device complexity while improving adaptability.
4Reliability
If detector assembly with pressurized gas is used to ensure light-safe contact, then safety reliability is improved, but device complexity increases
Solution Approach 1:
The detector assembly uses pressurized gas to automatically verify that the workpiece is in proper contact with the indexing member. The system self-checks the light-safe condition through gas flow detection, eliminating the need for manual verification and reducing operational complexity while maintaining high safety reliability.
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
Enables safe and efficient attachment of clinch nuts to advanced high strength steel sheets, enhancing safety for operators and improving the mechanical joining process by ensuring the steel sheet is heated sufficiently for ductility and secure fastening.
Implementation Method 1
A laser assembly fires a laser beam through the heating opening of the indexing member while in the heating position to provide heating of the work location of the AHSS sheet
Implementation Method 2
A detector assembly of the apparatus is operated by the controller to only permit operation of the laser assembly when the AHSS sheet is in light-safe contact with the indexing member around its heating opening... includes a source of pressurized gas for providing pressurized gas to the chamber and also includes a detector for detecting gas flow from the source through the chamber
Data Source
AI summary
Apparatus (20) and a method for securing a clinch nut (24) to an AHSS sheet (26) as an assembly (22). In one embodiment, a parallel kinematic machine (PKM) (88) sequentially performs the operation, while another embodiment includes a nut ram assembly (112) that attaches clinch nuts (24) to the AHSS sheet (26), and a further embodiment includes a C frame (114) that supports the apparatus and is moved by a robot (130) to sequentially attach clinch nuts (24) to the AHSS sheet (26) at different locations. The attachment of the clinch nuts is performed in a manner that contains laser beam radiation.