Metal Plate Coupling Member With Groove for Dissimilar-Metal Joining
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Solution Overview
Problem
Existing coupling technologies face challenges in efficiently joining metals with different melting points using a single pressure-electrification step, often resulting in insufficient contact and incomplete coupling due to the melting and solidification processes.
Innovation Solution
A coupling device employing a coupling member with a body, pilot portion, and ring-shaped wall, where the pilot portion and ring-shaped wall define a groove space, allowing the melted metal from a first plate to be discharged into the groove, ensuring sufficient contact and coupling with a second plate through resistance welding, while the controller manages the electrification and pressure application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single pressure-electrification step is used to join metals with different melting points, then the coupling process is simplified and productivity is improved, but insufficient contact and incomplete coupling occur due to melting and solidification processes
Solution Approach 1:
The coupling member is segmented into distinct functional portions: a body portion for structural support, a pilot portion for insertion and alignment, and a groove space for containing melted metal. This segmentation allows each portion to perform its specific function effectively, ensuring both productivity and reliability in the coupling process
Solution Approach 2:
The groove space acts as an intermediary between the first plate and second plate, receiving and containing the melted metal from the first plate. This intermediary structure ensures proper contact and coupling between the two plates while managing the melting and solidification process, resolving the contradiction between simplified single-step processing and reliable contact
2Reliability
If the groove space volume is sufficient to contain melted metal, then complete coupling is achieved, but the coupling member becomes more complex
Solution Approach 1:
The groove space is positioned locally at the leading end of the coupling member where the melting and coupling action occurs. This localized feature provides the necessary volume for containing melted metal without requiring the entire coupling member to be complex, achieving coupling completeness with minimal added complexity
Solution Approach 2:
The groove space is nested within the body of the coupling member, with the pilot portion extending from the body and the groove space positioned between them. This nested arrangement efficiently utilizes the coupling member's structure, providing sufficient groove volume without proportionally increasing overall complexity
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 reliable and efficient coupling of metals with different melting points in a single step, preventing incomplete contact and ensuring strong joints by melting and solidifying the metal within the groove space of the coupling member.
Implementation Method 1
The controller is configured to, while maintaining the contact state, control the power source to electrify the coupling member, the first plate, and the second plate while controlling the driver to apply pressure to the coupling member, the first plate, and the second plate so as to: melt a facing portion of the first plate facing the pilot portion of the coupling member
Implementation Method 2
melt and solidify the leading end of the pilot portion and the joint portion of the second plate to couple the leading end of the pilot portion and the joint portion of the second plate to each other
Data Source
AI summary
A coupling device is configured to, using a coupling member, couple a first plate made of a first metal and a second plate made of a second metal to each other, and includes a first electrode, a second electrode, a power source, a driver, and a controller. The power source is connected to the first electrode and the second electrode. The driver is configured to move the first electrode and the second electrode relative to the coupling member, the first plate, and the second plate. The controller is configured to control the power source and the driver to electrify the coupling member, the first plate, and the second plate while controlling the first electrode and the second electrode to apply pressure to the coupling member, the first plate, and the second plate.