Clinch Fastener Press Pin Sensing for Orientation Verification
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Solution Overview
Problem
Existing clinching presses face challenges in accurately detecting the proper orientation of fasteners, especially at increased automation speeds, leading to potential errors in the fastener loading process.
Innovation Solution
Incorporation of a pin sensor within the head assembly to monitor pin travel distance signatures, combined with a controller to determine the outcome of the clinching operation, along with additional sensors for feeder and slug detection, ensuring precise fastener positioning and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional sensors and switches are used to detect fastener presence and orientation, then measurement precision improves, but device complexity increases
Solution Approach 1:
The LVDT sensor serves multiple functions: it detects both the presence and orientation of the fastener by measuring the position of the head assembly, eliminating the need for separate sensors for each detection task. This multi-functional approach improves measurement precision while avoiding the complexity increase that would result from adding multiple dedicated sensors.
Solution Approach 2:
The invention uses the existing head assembly movement as a proxy indicator for fastener status. By measuring the displacement of the head assembly through the LVDT, the system indirectly detects fastener presence and orientation without requiring direct sensors on the fastener itself, simplifying the overall sensor configuration.
2Productivity
If automation speed is increased, then productivity improves, but measurement precision deteriorates
Solution Approach 1:
The LVDT sensor continuously monitors head assembly position before the clinching operation completes, allowing detection of fastener orientation issues early in the cycle. This preliminary detection capability enables the system to maintain high automation speeds while preserving measurement accuracy, as the detection does not depend on the final high-speed impact moment.
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
Enhances the accuracy and reliability of fastener installation by providing high-resolution monitoring of the clinching process, reducing errors and improving process verification.
Implementation Method 1
Typically, a linear variable displacement transducer (LVDT) has been connected to an exterior of a ram that carries the head assembly to measure the movement of the head assembly.
Implementation Method 2
The head assembly includes a magnet that is configured to maintain the fastener in engagement with the head assembly during the clinching operation.
Data Source
AI summary
A fastener clinching press includes a frame that supports a die having a hole that cooperates with the fastener to produce a slug from the workpiece. A ram has a head assembly that engages the fastener. A first sensor determines a ram position relative to the die. A pin is slidably supported within the head assembly and extends out of the head assembly to a tip that locates a fastener relative to the die. The pin is movable between multiple pin positions including a slug-eject position. A second sensor is arranged in the head assembly and is operatively connected to the pin. The sensor monitors the multiple pin positions that relate to a pin travel distance signature. A controller is in communication with the first and second sensors and determines an outcome of the clinching operation based upon the ram position and the pin travel distance signature.