Dual-Function Punch for Hole Punching and Press-Fitting
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Solution Overview
Problem
Existing setting units for connecting elements on workpieces, such as press-fit nuts and bolts, require additional operations like hole punching, which generates a punching slug that needs disposal, and face challenges in accessing complex component geometries, particularly in the motor vehicle industry, where fast cycle rates are crucial.
Innovation Solution
A setting unit with a hold-down clamp and a punch that can perform both hole punching and press-fitting operations using a dual-function punch, where the punch and punch sleeve move together to a first stroke position for press-fitting and then uncouple for hole punching, utilizing a mechanical forced guidance and a groove-pin guide for rotational movement, and an ejector pin is actuated passively by springs for slug ejection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate hole punching and press-fitting operations are performed, then manufacturing precision is improved, but productivity deteriorates due to additional operations and cycle time
Solution Approach 1:
The patent combines hole punching and press-fitting operations into a single integrated setting unit. The punch tool performs both functions sequentially: first punching the hole through the workpiece, then pressing the connecting element into the punched hole without requiring tool change or repositioning. This merging of operations eliminates idle time between steps while maintaining the precision requirements of both operations.
Solution Approach 2:
The punch tool is designed as a multi-functional element that can perform both hole punching and press-fitting operations. The same punch tooling is used for creating the hole and subsequently for installing the connecting element, making the tool universal for both operations. This eliminates the need for separate specialized tools while maintaining operational precision.
2Ease of operation
If a conventional setting unit is used for complex geometries, then ease of operation is maintained, but accessibility to fastening points deteriorates
Solution Approach 1:
The setting unit is mounted on a robotic manipulator that provides dynamic positioning capabilities. The robot can move the setting unit to various angles and positions to access difficult-to-reach fastening points on complex bodywork components. The setting unit itself maintains a simple operational mechanism while the robotic system provides the adaptability needed for complex geometries.
3Manufacturing precision
If hole punching is performed separately before press-fitting, then manufacturing precision is improved, but loss of time increases due to additional operations
Solution Approach 1:
The setting unit performs hole punching and press-fitting as continuous operations without interruption. The punch completes the hole punching motion, then immediately transitions to the press-fitting motion for the connecting element. This continuous action eliminates the time loss associated with stopping, repositioning, or changing tools between operations while maintaining the precision of both steps through controlled motion sequences.
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 design enables rapid and efficient setting of connecting elements with reduced operations, eliminating the need for separate hole punching and press-fitting steps, and allows for easier access in complex geometries, enhancing cycle rates and operational efficiency.
Implementation Method 1
A compensating spring acts on a head of the ejector pin by way of a rocker arm
Implementation Method 2
A return spring, which is arranged concentrically with respect to the ejector pin, acts on the ejector pin in opposition to the axial direction
Data Source
AI summary
A setting unit and a method for setting a connecting element on a work piece. The setting unit has a hold-down clamp. A punch is displaceably mounted in the hold-down clamp, is drivable in a feed direction by way of a plunger and has a front punch head, and a punch sleeve which surrounds the punch head. The punch sleeve is movable together with the punch in the feed direction to a first stroke position. The punch head is movable relative to the punch sleeve to a second stroke position such that it is possible to carry out both a hole punching operation and a setting operation by way of the one punch in connection with the punch sleeve.