Component Connection Using Position-Detection Electronics
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Solution Overview
Problem
Current methods for connecting components in large-scale vehicle body production are inefficient and costly, lacking in achieving high-strength connections suitable for mass production.
Innovation Solution
A method involving a connecting element protruding from one component and a clip element clipped onto it, with precise positioning using position-detection electronics, followed by welding and optional adhesive application, to securely join two components with high accuracy and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex clamping and mounting technology is used to position components, then positioning accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical clamping and mounting systems with a laser-based positioning system. Position-detection electronics, including optoelectronics or camera systems, detect the spatial position of the hole in the second component, and an electronically controlled welding device (welding robot) positions the connecting element based on detected coordinates, eliminating the need for complex mechanical positioning apparatus
Solution Approach 2:
The patent uses optical copying and data representation to transfer position information. The position-detection electronics create a digital representation of the hole's spatial position, which is then used to guide the welding robot without requiring physical mechanical guides or clamps
2Productivity
If welding is performed before positioning, then production speed is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent performs positioning actions before the welding action. The two components are first brought together and positioned relative to one another using the position-detection electronics and welding robot, ensuring high joining accuracy. Only after precise positioning is achieved is the connecting element welded to the first component, maintaining both precision and efficiency
3Adaptability or versatility
If manual connection methods are used, then adaptability to different materials is improved, but productivity decreases
Solution Approach 1:
The patent replaces manual connection methods with an electronically controlled welding device (welding robot) that can be programmed to weld different materials including metal-to-metal and metal-to-plastic combinations. This automation maintains material adaptability while dramatically increasing productivity for mass production applications
Solution Approach 2:
The welding process parameters can be electronically adjusted to accommodate different material combinations (steel, aluminum, plastic). The welding robot can modify welding current, speed, and other parameters based on the specific materials being joined, maintaining versatility across different material types while enabling automated high-speed production
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 easy, cost-effective, and high-strength connections in large-scale production by ensuring precise alignment and secure holding of components, suitable for various materials including metals and plastics, with the potential for automated processes.
Implementation Method 1
Provision can be made for the position detection electronics to have optoelectronics or a camera system, by means of which the spatial position of the hole is detected optoelectronically
Implementation Method 2
Various welding processes can be considered, e.g. laser welding, resistance current welding, friction welding
Implementation Method 3
Various welding processes can be considered, e.g. laser welding, resistance current welding, friction welding
Implementation Method 4
a clip element is clipped onto the connecting element, which holds the two components together
Data Source
Figure 1~3
AI summary
Method for connecting a first component (1) to a second component (2) having a through hole (4), comprising the following steps: bringing the two components (1, 2) against one another and positioning them relative to one another, detecting the spatial position of the hole (4) by means of a position detection electronic unit, positioning a connecting element (5) at a point within the hole (4) as a function of the spatial position of the hole (4) or as a function of position data determined by the position detection electronic unit, connecting the connecting element (5) to the first component (1), with the result that the connecting element (5) projects into or through the hole (4), and clipping onto the connecting element a clip element (6) which holds the two components (1, 2) together.